Liebherr D 924T-E TI-E D926 T-E TI-E Engine Operating Manual SN2000010000 - PDF DOWNLOAD

en O

Operating manual

valid from serial no.: - 2000010000 BAL: 9076418

Please enter the following details on receipt of your vehicle: *You will find these details on the vehicle type plate. They will be useful when ordering spare parts. * Vehicle identity no./ * Machine Serial No.:

. . . . . . .

* Year of construction/ * Date:

. . . . . . .

Initial start-up date

. . / . . / . .

Address Address:

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

Product identification LIEBHERR MACHINES BULLE S.A D924 T-E/TI-E - D926 T-E/TI-E 2000010000

Document identification Order number: Author: Document version:

9076418 LMB/Abteilung-BE-MD3 01

LIEBHERR D924 T-E/TI-E - D926 T-E/TI-E -/2000010000

LMB /01 /003801 //6.2/en /Version :

Manufacturer: Product group: Type: Construction number: Serial number: Conformity:

Foreword

This operating manual has been compiled for the operator and for the maintenance personnel concerned with the diesel engine It includes descriptions for: – Technical Data – Safety requirements – Service and operation – Maintenance The operating manual must be read thoroughly before initial start-up and at regular intervals thereafter, by all personnel contracted to work on/with the diesel engine, and must be strictly adhered to.

Tasks either with or on the diesel engine include for example: – Operation , care, disposal of fuels and consumables – Repair , including maintenance and inspection.

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This simplifies training of the operator for the diesel engine and prevents malfunctions due to unprofessional operation.

We hope that you will understand that all warranty claims resulted from unprofessional operation, inadequate maintenance, utilisation of impermissible fuels or negligence of the safety guidelines, will not be recognised by us.

LIEBHERR will annul any obligations concerning claims recieved by LIEBHERR and/or their dealers, including guarantees, service orders, etc. without notice, should any spare parts other than original LIEBHERR parts or parts manufactured by LIEBHERR be bought to carry out maintenance or repair tasks.

Under extreme conditions, it is possible that maintenance must be carried out more regularly than specified in the inspection plan.

Modifications, requirements, copyright.

– Modification of technical details of the machine as opposed the details and illustrations specified in the documentation included, remains reserved.

Warranty and liability requirements of the general terms of trade for the LIEBHERR company are not extended by the aforementioned references.

Details and illustrations of this manual may be either reproduced and distributed or be used for the purposes of the competition. All legal rights concerning the copyright remain exclusively reserved.

D924 T-E/TI-E - D926 T-E/TI-E -/2000010000 LIEBHERR

Contents

1

Product description 1.1

Technical data 1.1.1

1.2

2

1-3

Technical description

1-4

1.2.1

Explanation of model description

1-4

1.2.2

Structural features

1-6

1.2.3

Additional equipment

1-7

2-1

2.1

Introduction

2-1

2.2

General safety guidelines

2-1

2.3

Use as directed

2-2

2.4

Notes on preventing crushing and burns

2-2

2.5

Notes on fire-prevention and danger of explosions

2-3

2.6

Safety precautions for start-up

2-3

2.7

Measures for safe maintenance

2-3

2.8

Safety precautions for the diesel engine with electronic control equipment

2-5

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

2-5

Disposing of fuels

2-6

Operation, Handling

3-1

2.10

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1-3

Diesel engine

Safety regulations

2.9

3

1-1

3.1

Control and operating elements

3-1

3.2

Operation

3-2

3.2.1

Preparing for initial start-up

3-2

3.2.2

Maintenance tasks before daily start-up

3-3

3.2.3

Starting the diesel engine

3-3

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Operating manual

3.2.4 3.2.5

4

3-5

Putting out of operation

3-5

Malfunctions 4.1

5

Precautions when starting in frosty temperatures

Error code tables

Maintenance

4-1 4-1

5-1

5.1

Maintenance and inspection schedule

5-1

5.2

Lubricant chart, Filling quantities

5-4

5.3

5.2.1

Table of filling quantities

5-4

5.2.2

Lubricant chart

5-4

Maintenance tasks 5.3.1

Special tools for maintenance tasks

5-6

5.3.2

Prepatory tasks for maintenance

5-9

5.3.3

Maintenance tasks (daily) every 10 operating hours

5-9

Maintenance duties (weekly) every 50 operating hours

5 - 13

Maintenance tasks every 500 operating hours

5 - 14

Maintenance tasks every 1000 operating hours

5 - 21

Maintenance tasks every 2000 operating hours.

5 - 32

Maintenance tasks every 3000 operating hours.

5 - 34

5.3.9

Maintenance tasks as required.

5 - 40

5.3.10

Transport

5 - 46

5.3.11

Storage

5 - 46

5.3.12

Comfirmation of maintenance tasks carried out.

5 - 47

5.3.4 5.3.5 5.3.6 5.3.7 5.3.8

5.4

5-6

Lubricants and fuels

5 - 50

5.4.1

Handling lubricants and fuels

5 - 50

5.4.2

Lubricant and fuel specifications

5 - 51

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Contents

1 Product description Equipment layout This section includes a summary of the diesel engine with a description of the component displayed.

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Components of the diesel engine / viewed from front right-hand side 1 Injection lines 2 Injection nozzle 3 Flame heater glow plug 4 Transprt gear 5 Air suction pipe 6 Crank housing aeration

7 Flywheel 8 Cylinder head 9 Crankshaft/Drive components 10 Aggregate carrier 11 Solenoid valve/ Flame-heater starter

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12 Generator 13 Manual conveyor pump 14 Injection pump 15 Fuel filter 16 Oil cooler 17 Oill filter

1-1

Product description

Operating manual

Components of the diesel engine / View from front left-hand side 7 Flywheel housing 8 Air compressor 9 Diesel engine brake 10 Fan 11 Oil filler 12 Exhaust pipe

13 Water collection line 14 Cylinder head cover 15 Coolant pump 16 Water filter

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1 Air compresser 2 Crank housing 3 Turbocharger 4 Starter 5 Oil dipstick 6 Oil pan

1-2

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Operating manual

Product description Technical data

1.1 Technical data 1.1.1 Diesel engine

Diesel engine Name

Value

Design

In-line diesel engine

Number of cylinders (D924) Firing order (D924) Number of cylinders (D926) Firing order (D926)

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Cylinder head.

1–3–4–2 6 1–5–3–6–2–4 122

mm

Stroke

142

mm

Displacement (D924)

6.64

litres

Displacement (D926)

9.96

litres

Compression ratio

17,2:1 left

Performance group

LG1 to LG5

Performance data per

ISO 9249

Power rating

see engine identification plate

kW

Power rating

see engine identification plate

min -1

Emission limit values

97/68/EG / EPA/CARB

D924 Weight of engine (without water, without oil)

approx. 710

kg

D926 Weight of engine (without water, without oil)

approx. 900

kg

Name

Value

Units

see engine identification plate

°KW vOT

Name

Value

Units

Cracking pressure, new

225 +8

bar

Cracking pressure during operation

217 +8

bar

Name

Value

Units

Valve clearance - intake/cold

0.25

mm

Valve clearance - exhaust/cold

0.30

mm

Begin of delivery with OT

Injection nozzle.

4

Bore

Direction of diesel engine rotation (when facing flywheel)

Injection pump.

Units

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1-3

Product description

Operating manual

Technical data

Coolant pump

Name

Value

Flow rate (at nominal engine speed 2000 min -1 and counter pressure 0.6 bar) Coolant thermostat

Generator

Name

Value

Flywheel housing

Units

79

°C

Completely opened

92

°C

Name

Value

Voltage

28

V

55 / 80 / 120

A

Name

Value

Voltage

24

Output

5.4 / 6.6 / 9

Name

Value

Connection Air compressor

l

Beginning of opening

Amperage Starter

408

Units

Units

Units V kW Units

SAE1 / SAE2

Name Flow rate (1 cyl.) at nominal engine speed of 2000 min -1 and 6 bar Ratio of transmission

Value

Units

464

l/min

1 : 1.275

Water-cooled

yes

1.2 Technical description 1.2.1

Explanation of model description

D D

92

6

T

I

–E

92 6 T I –E

1-4

Beschreibung Typbezeichnung Dieselmotor Bohrung 122 mm, Hub 142 mm Anzahl der Zylinder (6 Zylinder) Turbomotor Ladeluftkühlung Emissionsoptimiert

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Model description

Operating manual

Product description Technical description

Diesel engine idenification plate

The diesel engine identification plate is mounted on the right-hand side of the crank housing as viewed facing the flywheel. A second identification plate may have been mounted on the air suction pipe depending on the design

Identification plate Diesel engine number

The diesel engine number has been stamped onto the diesel engine identification plate and on the crank housing. The diesel engine number on the crank housing is located at the end of the cover surface of cylinder 4 or 6, according to the diesel engine's number of cylinders.

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Diesel engine number 1 Number of years ( 2 or 4 digit) 2 Number of cylinders ( 01=4 cylinder, 02=6 cylinder )

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3 Serial number

1-5

Product description

Operating manual

Technical description

Cylinder description, direction of rotation

Cylinder description — Direction of rotation

1-6

1.2.2

Structural features

Design

Water-cooled 4 and 6 cylinder in-line diesel engine with LIEBHERR direct fuel injection and exhaust turbocharging.

Features

Increased operational safety and longer life-expectancy are assured via the robust basic design and oversized components. Due to constructive optimisation, fuel consumption, as well as exhaust and noise emissions, have been reduced. Reduced maintenance to easily accessible components and extensive mounting possibilities for special attachments contribute considerably to the overall economy of the diesel engine.

Transmission

The 4 cylinder diesel engines feature a 5-way mounted steel crankshaft (Split Pin) / the 6 cylinder diesel engines feature a 7-way mounted steel crankshaft with inductive reinforced bearing surfaces and 4 / 8 forgrd counterweights.

A torsion vibration damper has been mounted to the crankshaft on the fan side Forge-pressed connecting rod cut at an angle, Triebwtransmission mounting in lead bronze triple substance glide bearings or sputterlager.

Smooth-rod three-ring pistons made of aluminium alloy with ring carrier and combustion chamber in the base of the piston. Replaceable wet cylinder liners

Housing

One-piece crank housing made of alloyed cast iron. Single cylinder heads with cast twist inlet port as well as replaceable valve seat insert and valve guides.

Flywheel housing, front aggregate carrier and oil pan mounted on the underside encapsulate the diesel engine.

Drive control

Each cylinder features an intake and exhaust valve suspended in the cylinder head (ohv.). Actuated by 5-way or 7-way mounted steel camshafts via duplex metal tappet, push rod and rocker arm. Drive created by camshaft, injection pump, lube oil pump, air compressor, water pump and auxiliary hydraulic pumps of the crankshaft via nitrified gears mounted on the side of the fan.

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Cylinder 1 is mounted on the side of the flywheel. The cylinder numbers, as well as the firing order, have been printed on the top surface of the crank housing on the right hand side as viewed facing the flywheel.

Operating manual

Product description Technical description

Lubrication

Circulating forced lubrication with gear pump for crankshafts, connecting rod and camshaft bearing as well as piston pin bushing, tappet and rocker arm.

Oil filtering via two replaceable cartridge filters in the main power supply.

Auxiliary aggregates such as injection pump and air compressor are connected to the diesel engine lube oil circuit. The diesel engine oil cooler has been integrated in the cooling water current.

Cooling

Double-thermostatic regulated liquid cooling with centrifugal pump, individual supply to each cylinder unit via cast distributor channels in the crank housing.

Piston cooling via spraying oil of the diesel engine's lube oil circuit.

Injection system and regulation

Maintenance-free BOSCH inline injection pump with mechanical BOSCH centrifugal force regulator or electronic regulator (EDC) , or distributor injection pump with mechanical BOSCH centrifugal force regulator , fuel filter, BOSCH six-hole nozzles.

Flame-start system

The flame-start system is cold start aid for extremely low ambient temperatures. When the diesel engine is started, it reduces the emission of white smoke.

Starter and batteries are preserved due to the shortening of the start time.

The flame glow plug mounted in the air suction pipes are supplied with fuel via a solenoid valve with dosing nozzle and can be ignited.

Electrical equipment

Starter and alternator: 24 Volt.

Electronic sensors on the engine side

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1.2.3

Charge air pressure sensor, temperature sensor for coolant and charge air, speed sensors and oil pressure sensor are interfaces for internal monitoring and control functions. The individual functions and error reports are described in the respective user documentation.

Additional equipment

Diesel engine brake

The diesel engine exhaust brake flap is installed in the exhaust line channelled from the exhaust turbo-charger to the muffler. The diesel engine exhaust brake flap is actuated via a cylinder pressurised with compressed air, and the diesel engine's braking action is effected by closing of the diesel engine exhaust brake flap.

Diesel engine brake and auxiliary brake system

To increase the diesel engine braking action, a diesel engine auxiliary brake system (ZBS) has been installed additionally to the diesel engine exhaust brake flap. The ZBS thus increases braking action by opening a gap in the exhaust valve during diesel engine braking procedure.

Electromagnetic fan coupling

The hydraulic constant motor with mounted fan is flange-mounted directly to the front side of the diesel engine. Regulation and the hydraulic drive of the hydraulic constant motor is resulted from the user system.

Electronic diesel engine regulation

The electronic diesel engine regulator (EDC) serves the regulation of speed and torque for the LIEBHERR diesel engines during operation of vehicles and aggregates.

The regulator carries out all functions of the mechanical regulator (complete speed regulation, torque regulation, torsional moment limitation, LDA function) and provides further functions (diagnosis of CAN and vehicle management) depending on application and utilisation.

The EDC is comprised essentially of the sensors, the control unit and the actuator. Devices on the diesel engine side and vehicle/plant side are connected to the EDC control unit via separate, prefabricated cable harnesses. Communication between diesel engine control unit and machine control is resulted via CAN (Control-Area-Network).

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1-7

Product description

Operating manual

Technical description

The air compressor is mounted directly to the diesel engine and driven via a magnetic coupling with a ribbed V-belt. With the air conditioning activated, the magnetic coupling is active and the compressor is working.

Air compressor

The air compressor is flange-mounted to an auxiliary drive integrated in the aggregate carrier. Cooling or lubrication of the air compressor is connected to the respective circuits of the diesel engine.

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Air compressor

1-8

LIEBHERR D924 T-E/TI-E - D926 T-E/TI-E -/2000010000

2 Safety regulations Work on the diesel engine could prove to be hazardous for the user, the operator or the maintenance personnel. Danger and accident can be thoroughly prevented by regular, conscientious reading and adherence of the notes on safety.

This applies in particular for personnel working opportunely on the diesel engine, carrying out repair tasks for example.

Safety guidelines have been specified as follows, the conscientious adherence of which guarantees your safety, the safety of others and the prevention of damage to the diesel engine.

For all tasks which may lead to hazardous situations for personnel or the diesel engine, the necessary safety precautions are described in this book accordingly.

They are signified via the notes– Danger , Warning or Caution

2.1 Introduction 1.

2.

In this book the notes mean, Danger warns against certain working procedures, which, without the necessary safety measures having been taken, could lead to fatalities. „Warning„ warns against certain working procedures, which, without the necessary safety measures having been taken, could lead to serious mortal injury.

Caution warns against certain working procedures, which, without the necessary safety measures having been taken, could lead to injury or damage to the engine.

Adherence of these notes does not warrant negligence of the other rules and regulations!!

The safety regulations valid for the jobsite must also be noted.

2.2 General safety guidelines

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1.

2.

3.

4.

Before starting up the machine, familiarise yourself with operation and maintenance.

Ensure that all additional instructions concerning special equipment for your machine are retained about your person or have been thoroughly read and understood.

Only expressly authorised personnel may operate or carry out maintenance and repair tasks to the diesel engine.

Observe the legal age requirement.

Allow only trained or instructed personnel to carry out operation, set-up, maintenance or repair tasks, and ensure that all personnel are aware of their responsibilities.

All personnel undergoing training, being instructed or other personnel involved with general development, must be supervised at all times by an experienced person when carrying out work to the diesel engine.

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2-1

Product related security provisions

Operating manual

General safety guidelines

5.

6.

Check at least opportunely, that tasks are being carried out conscientiously regarding safety and danger by pesonnel in acordance with the operating manual.

Always wear protective clothing when working on the diesel engine.

Avoid wearing rings, wrist watches, ties, scarves, open jackets, clothing which is not tight-fitting, etc. Danger of accident due to getting caught up or getting dragged in for example.

2.3 Use as directed 1.

2.

3.

This diesel engine has been built exclusively for the purpose corresponding to the delivery scope, as defined by the machine manufacturer (use as directed): Any utilisation of the machine not in accordance is deemed not use as directed. The manufacturer is not responsible for any resulting damage. The operator is solely responsible.

Adherence of the manufacturer's prescribed operating, maintenance and repair requirements are also included as use as directed. Operation, maintenance and repair of the diesel engine may only be carried out by personnel which are familiar with the tasks and have been instructed about the dangers.

Any resulting damage caused by unauthorised modifications to the diesel engine invalidate liability of the manufacturer.

Manipulations to the injection and regulation systems can also influence performance and exhaust procedures of the diesel engine and compliance of the legal conversational conditions can no longer be guaranteed.

1.

2.

3.

4.

5.

6.

2-2

Do not use any ropes or chains which are damaged or do not have sufficient load capaity.

Wear industrial gloves when handling wire ropes.

When the diesel engine is running, ensure that no objects may come into contact with the fan.

Any objects either falling into or protruding into the fan are flung back out again or destroyed, and this may damage the fan.

When approaching operating temperature, the diesel engine cooling system is hot and under pressure.

Avoid any contact with parts carrying cooling water.

Danger of burns!

Only check the cooling water level if the sealing cover of the expansion tank has cooled down enough to be able to touch it.

Open the cover carefully in order that the overpressure can be dissipated.

Diesel engine oil is hot when approaching operating temperature.

Avoid skin contact with hot oil or parts carrying oil.

Wear protective glasses and industrial gloves when working on the batteries.

Avoid also sparks and naked flames.

LIEBHERR D924 T-E/TI-E - D926 T-E/TI-E -/2000010000

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2.4 Notes on preventing crushing and burns

Operating manual

Product related security provisions Notes on fire-prevention and danger of explosions

2.5 Notes on fire-prevention and danger of explosions 1.

2.

3.

4.

5.

6.

7.

The diesel engine must be switched off when refuelling.

Do not smoke and avoid any naked flames when refuelling or in the area where the batteries are charged.

Always start the diesel engine in accordance with the guidelines in the operating and maintenance manuals.

Check the electrical system.

Remedy all errors, such as loose connections and shorn cables immediately.

Check all lines, hoses and threaded connections regularly for leaks and damage.

Remedy all leaks immediately and replace damaged components.

Fires can be easily started via oil being sprayed from leak points.

The starter pilot (ether) is particularly fire-hazardous.

Never use ether-based cold start aids near heat sources, naked flames (e.g. cigarettes) or in poorly ventilated areas.

2.6 Safety precautions for start-up 1.

2.

3.

Unless instructed otherwise, start the diesel engine in accordance with the guidelines in the Operating and Maintenance Manual .

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

Do not run the diesel engine in enclosed areas with insufficient ventilation.

If necessary, open all doors and windows in order that a suuficient supply of fresh air is guaranteed.

2.7 Measures for safe maintenance 1.

2.

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3.

4.

5.

6.

Do not attempt any maintenance or repair tasks with which you are not competent.

Adhere to the prescribed intervals, or intervals specified in the operating manual, for recurring checks and inspections.

When carrying out repair measures, it is imperative that one of the workshop tools suitable for the task is used.

Using the list at the end of this Operating and Maintenance Manual , you can define precisely which tasks may or must be carried out.

Tasks listed under daily/ weekly in the maintenance chart may be carried out by the machine operator or maintenance personnel.

All other tasks may only be carried out by specialist personnel with the appropritae training.

Spare-parts must correspond with the technical requirements determined by the manufacturer. This is always guaranteed when using original spare parts.

Always wear protective clothing when carrying out maintenance tasks.

Unless otherwise stated in this Operating and Maintenance Manual , carry out all maintenance tasks to the diesel engine on firm, even ground and with the diesel engine switched off.

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2-3

Product related security provisions

Operating manual

Measures for safe maintenance

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

2-4

When carrying out maintenance and repair tasks, always tighten loosened screw connections.

Clean the diesel engine, and in particular the connections and threaded unions, of oil, fuel or other agents before beginning any maintenance or repair tasks. Do not use any aggressive cleaning agents. Use fibre-free cleaning cloths.

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

Before cleaning the machine with water, steam-jet (high-pressure cleaner) or other cleaning agents, cover or seal all openings in which water,steam or cleaning agent could penetrate, for reasons of safety and functionality.

The KG-exhaust, WP-exhaust, electrics box, starter and alternator are at particular risk.

Additional procedure: – After cleaning, remove the covers and seals completely.

– Inspect all fuel, diesel engine oil lines and hydraulic oil lines for leaks, loosened connections, wear points and damage following cleaning.

– Remedy all determined faults immediately.

Note the safety guidelines applicable for the product when handling oils, grease and other chemical substances.

Ensure safe and environmentally-protective disposal of fuel and lubricants, as well as replacement parts.

Take care when handling hot fuel and lubricants (danger of burning and scolding).

Always industrial gloves when searching for leaks. A fine liquid jet under pressure can penetrate the skin.

Switch off the diesel engine before loosening the oil lines.

Only operate combustion engines and fuel-powered heating in sufficiently ventilated areas. Ensure sufficient ventilation when starting up in enclosed areas. Adhere to the valid guidelines which apply for the respective jobsite.

Try to avoid lifting heavy parts. Use a suitable lifting gear with sufficient lift capacity.

Procedure: – Fix and secure individual parts and larger aggregates carefully to the lifting gear when replacing in order that no danger is resulted.

– Use only suitable and technically sound lifting gear, as well as load carrying gear with sufficient lifting capacity.

Standing or working beneath a suspended load is prohibited.

Do not use any damaged ropes or ropes which have insufficient lifting capacity. Wear industrial gloves when handling wire ropes.

Working on the machine's electrical equipment may only be carried out by an electrical specialist or by a qualified person under the supervision and guidance of an electrical specialist in accordance with the respective electrotechnical regulations.

Disconnect the batteries if tasks are to be carried out to the electrical system or if electric welding work is to carried out on the machine.

Always diconnect the negative terminal first and reconnect last.

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7.

Operating manual

Product related security provisions Safety precautions for the diesel engine with electronic control equipment

2.8 Safety precautions for the diesel engine with electronic control equipment 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Only start the diesel engine with batteries securely connected.

Do not disconnect the batteries with the diesel engine running.

Only start the diesel engine when the diesel engine is connected.

Do not use a quick-charger when starting the diesel engine. Only use jump-leads with separate batteries.

For quick-charging of the batteries, the battery terminals must be removed.

Refer to the operating manual of the quick-charger.

The batteries must be disconnected for electric welding tasks and both cables (+ and —) must be securely connected with each other.

The connections of the control equipment may only be removed or unplugged when the electrical system has been switched off.

Wiring the terminals of the control equipment-voltage supply (e.g. due to incorrect wiring of the battery terminals) can cause damage to the control equipment.

Tighten connections on the injection system to the prescribed tightening torque.

With temperatures expected to exceed 80 °C (e.g. seasoning kiln), the control equipment must be dismantled.

Only use suitable test leads for measurements at the plug connections.

Telephones and radios which are not connected to an exterior antenna can lead to malfunctioning of the vehicle electrics and thus endanger operational safety of the diesel engine.

2.9 Safety and emergency operation program for diesel engines with electronic control equipment

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1.

The diesel engine features an electrical regulation system, which monitors the diesel engine as well as the system itself (self-diagnosis) As soon as a fault has been determined, it is evaluated and one of the following measures will be initiated: – Issue of an error report with error code.

– The error code is issued directly via a display in connection with the vehicle-diagnosis-system.

– Switching over to the appropriate auxiliary functions for further, however limited operation, of the diesel engine (e.g. constant emergency operation speed) Have faults remedied immediately by the LIEBHERR after-salesservice responsible..

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2-5

Product related security provisions

Operating manual

Disposing of fuels

2.10 Disposing of fuels 1.

2.

3.

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4.

Ensure when handling fuels that no fuel escapes onto the ground, into sewage systems or bodies of water.

Different fuels should be collected and disposed of in separate containers.

Use thick containers for draining the fuel into. Under no circumstances should recepticles for foodstuffs or drinks be used as somebody may inadvertantly drink from it.

Before disposing of, or recycling waste products, enquire as to the correct methods regarding the respective environmental or recycling plant.

Incorrect disposal of waste products may damage the environment and the ecology.

2-6

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3 Operation, Handling

3.1 Control and operating elements

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The diesel engine must be operated or controlled via the following elements: – Electronic inspection lamp indicates the operating condition of the diesel engine.

– Oil pressure display indicates the diesel engine oil pressure – Amperemeter or charge control lamp indicates the charge amperage in the electrical system.

– Coolant thermometer indicates the temperature of the diesel engine coolant – Tachometer indicates the diesel engine speed in RPM – Hour meter indicates the hours the diesel engine has been operated The hour meter must be operated for the time schedule of a regular maintenance.

– Air filter maintenance display indicates the degree of contamination in the air filter.

– Speed regulation regulates speed of the diesel engine

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3-1

Operation, Handling

Operating manual

Operation

3.2 Operation

3.2.1

Preparing for initial start-up Caution !

Should the application area for the diesel engine be 3000 metres above sea-level, the output must be reduced in accordance with consultation with the factory. If the ouput is not reduced, the diesel engine will become thermally overloaded and will lead to failure.

Brand new diesel engines have been filled in the factory with oil specially blended for initial operation. Engines which have undergone an overhaul or immersed engines are usually delivered without fuel.

The valuable oils for initial operation favour the run-in process and alow the first oil-change to be carried out in accordance with the first oil-change at normal oil-change intervals.

Filling amounts and quality, see chapter Fuel and Lubricants, Specifications .

Filling in fuel Füllen Sie folgende Betriebsstoffe vor der Erstinbetriebnahme ein: – Diesel engine oil Authorised diesel engine oil for overhauled or immersed engines, see chapter Using Fuel and Lubricant Specifications – Coolant For coolant composition, see chapter Fuel and Lubricants, Specifications .

– Fuel Use summer or winter fuel depending on the season. Diesel fuels must comply with the permissible fuel specifications, see chapter Fuel and Lubricants, Specifications – Ensure utmost cleanliness, use sieve with funnel. Should refuelling be resulted from barrels or canisters, note the safety guidelines, see chapter Safety Guidelines . It is imperative that the penetration of water be avoided.

Carry out the following preparations after refilling fuel:

•

Lubricate cardan shafts, rods, ball heads, grease nipples and spur gears with oil or grease.

• • • •

Check batteries. Only use sound, filled and maintained batteries.

Bleed fuel system. ( see chapter, Maintenance)

Check oil pressure display immediately after starting the diesel engine.

No oil pressure has been achieved within 5 seconds?

3-2

• •

Switch off diesel engine immediately.

• •

Carry out a test run in accordance with the preparations described.

Determine and remedy cause.

Only increase diesel engine speed gradually up to 3/4 of the highest permissible speed until operating temperature has been reached.

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Start diesel engine

Operating manual

Operation, Handling Operation

Tasks during and following the test-run Bleeding the cooling system:

•

Allow diesel engine to run for approx. 5 minutes at medium speed.

Check coolant level again and refill if necessary.

•

If heating is connected to the cooling system, all heating valves must be opened before refilling. They should only be closed again after running the diesel engine for a short while and possibly refilling the heating valves.

Check diesel engine oil level:

•

When the diesel engine has been shut down for 2 or 3 minutes, check the diesel engine oil level and if necessary, refill oil up to the maximum marking on the oil dipstick.

Checking the diesel engine

• •

3.2.2

Checking the diesel engine for leaks.

Check hose connections, hose clips and pipe connections throughout the entire system for leaks and tension, and tighten if necessary.

Maintenance tasks before daily start-up Before daily start-up, carry out the maintenance tasks (daily) every 10 operating hours (see hapter Maintenance).

3.2.3

Starting the diesel engine Start procedure Only set the diesel engine into operation if you have read, and have complete understanding of, the operating manual.

•

If fuel shut-off taps are available: Open fuel shut-off tap.

•

Position speed adjusting lever to 1/3 of full throttle.

Operating manual or When the diesel engine is warm: Allow diesel engine to run in idle.

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•

Start diesel engine via the ignition key.

or

Start diesel engine via the starter push-button.

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Operation, Handling

Operating manual

Operation

The starting procedure has still not been successful after approx. 20 seconds?

• •

Initiate a pause of 1 minute.

•

After start-up, warm up the diesel engine for a short time with medium load.

•

Check oil pressure display immediately following start-up of the diesel engine.

Oil pressure is not displayed within 5 seconds.

Swith off diesel engine immediately.

– –

If this procedure has already been carried out three times: Determine and remedy cause of error.

Operation

• – – – – –

Checking diesel engine during operation.

Oil pressure is constant.

Output and speed are constant.

Exhaust has no colour.

Coolant temperature is stable.

Diesel engine sound is normal.

Faults have been determined?

•

Switch off diesel engine immediately.

Fan coupling

•

3-4

Screw in the two screws, M 6x10 through the angle in the thread in the cooling finned ring securely.

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Note: When mounting an electromagnetic fan coupling on the fan drive, the fan coupling may become mechanically blocked if the drive speed of the fan drive has not been reached, e.g. due to a malfunction in the power supply etc. .

Operating manual

Operation, Handling Operation

3.2.4

Precautions when starting in frosty temperatures Low temperatures The starting procedure is thus improved in low temperatures:

Warning

Danger of diesel engine exploding!

When using ether-based starting aids for starting the diesel engine with pre-heating system, there is a serious risk of explosion! ! Dispensing of ether-based starting aids.

Winter operation

3.2.5

• •

Check battery charge.

•

Use winter fuel (see chapter „Fuel and Lubricants„ under winter operation).

If battery charge is not sufficient Recharge battery.

Putting out of operation Switching off the diesel engine

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Caution

Risk of damage to the diesel engine!

If the diesel engine is shut down suddenly, the turbocharger continues running for a short while without oil supply. ! Do not switch the diesel engine off suddenly when at full load speed. This should be noted in particular with turbo-diesel engines.

Starter switch – 0-position

• •

Reducing the diesel engine speed to idle speed.

•

Turn contact key to position 0 - and remove.

Allow the diesel engine to run on for approx. 10 to 15 seconds without load in idle.

The diesel engine is switched off.

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4 Malfunctions Die Störungssuche bei Dieselmotorproblemen kann schwierig sein. Für mögliche Dieselmotorprobleme mit vermuteter Ursache und Korrekturmaßnahme siehe Tabelle Störungssuche.

Note: For diesel engines with electronic EDC regulation, additional error codes are displayed on the Display equipment for diagnosis should any errors arise, and are descibed in the respective machine documentation.

Fundamental steps of thought for diagnosis are included in the following list: – Getting familiar with the diesel engine and the respective systems.

– Analyze problem thoroughly.

– Relate the symptoms in accordance with previous knowledge of the diesel engine and the systems.

– Diagnose the problem whereby the simplest hypothesis will be used.

– Carry out a check before beginning dismantling.

– Determine causes and carry out repairs thoroughly.

– After repairing the diesel engine, allow it to run under normal conditions and check as to whether the problem and the cause have been remedied.

4.1 Error code tables Error Starter not turning or too slow

Cause Battery insufficiently charged

Starter magnetic switch faulty

Charge battery Tighten cable at terminal, if necessary, solder on new terminal Have inspected by a specialist

Fuel tank empty

Refuel, bleed fuel system

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

Clean or replace filter element

Connecting cable to starter is loose Diesel engine will not start or cuts out again immediately

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Fuel not cold-resistant Ambient temperature too low Flame heater system faulty (with cold temperatures) Diesel motor not starting smoothly

EDC-control unit faulty Leaks or too low a pressure in the fuel low pressure circuit

Diesel engine shuts down suddenly

Remedy

Clean and bleed system Seal up Clean pre-filter, replace fuel filter; use winter fuel Note measures for winter operation Check solenoid valve and glow plugs and replace if necessary Read out error memory EDC-control unit Consult LIEBHERR AFTERSALES-SERVICE Check of seals (visual inspection); have inspected by LIEBHERR AFTERSALES-SERVICE

EDC-control unit faulty (complete breakdown);

Consult AFTER-SALES-SERVICE

Voltage supply interrupted

Consult LIEBHERR AFTER-SALESSERVICE

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Malfunctions

Operating manual

Error code tables

Diesel engine shuts down suddenly Poor diesel engine output (defect in performance)

Cause Leaks or too low a pressure in the fuel low pressure circuit or drive fuel conveyor pump faulty Charge pressure sensor faulty Charge air temperature too high or temperature sensor faulty Cooling temperature too high Diesel engine brake flap faulty Fault in the fuel system (clogged, leaking) Injection nozzles get caught or are not spraying Engine compression too low

EDC-control unit faulty Poor diesel engine braking action

EDC-control unit faulty Diesel engine brake flap faulty

Diesel engine steadies too early Faulty or incorrectly parametered (max. speed can not be EDC-control unit reached) Diesel engine becomes too hot (in accordance with the display Coolant temperature sensor faulty coolant temperature) Too little coolant, or cooling system not completely bled Interior of cooler contaminated or calcified, cooler strong outside Thermostat faulty Charging current indicator lamp lights up when the diesel engine Tension of ribbed V-belt insufficient is running Ribbed V-belt broken Generator, rectifier or regulator faulty Diesel engine producing black smoke

4-2

Injection nozzles get caught or are not spraying

Remedy Check of seals (visual inspection); have inspected by LIEBHERR AFTERSALES-SERVICE Check charge pressure sensor and replace if necessary; Consult LIEBHERR AFTER-SALES-SERVICE Check temperature sensor and replace if necessary; consult LIEBHERR AFTER-SALES-SERVICE Check temperature sensor and replace; consult LIEBHERR AFTERSALES-SERVICE Functional or visual inspection; consult LIEBHERR AFTER-SALES-SERVICE Visual inspection for leaks, replace filter, consult LIEBHERR AFTERSALES-SERVICE Check, adjust or replace injection nozzles, consult LIEBHERR AFTERSALES-SERVICE Check valves, pistons and cylinders and replace if necessary, consult LIEBHERR AFTER-SALES-SERVICE Read out error memory EDC-control unit, consult LIEBHERR AFTERSALES-SERVICE Read out error memory EDC-control unit, consult LIEBHERR AFTERSALES-SERVICE Functional or visual inspection; consult LIEBHERR AFTER-SALES-SERVICE Read out error memory EDC-control unit, consult LIEBHERR AFTERSALES-SERVICE Replace sensor Refill ,bleed Clean or decalcify Check and replace if necessary; consult LIEBHERR AFTER-SALES-SERVICE Check belt tension anf if necessary, replace the tensioning pulleys Replace ribbed V-belt Check; consult LIEBHERR AFTERSALES-SERVICE Check, adjust or replace injection nozzles, consult LIEBHERR AFTERSALES-SERVICE

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Error

Operating manual

Malfunctions Error code tables

Error Diesel engine producing black smoke

Cause Turbocharger or charge air pipe faulty, air filter contaminated Diesel engine brake flap faulty

Exhaust is blue

Oil level in diesel engine too high.

Lube oil is being directed into the combustion chamber and is being burned. Clearance between the valve shaft and the valve guides too great, piston rings worn, broken or have siezed, signs of corrosion to the pistons and cylinder liners.

Sealing on the compressor side of the exhaust turbocharger faulty

Exhaust is white

Cylinder head or cylinder head seals leaking, coolant is being directed into the combustion chamber

Diesel engine knocking

Combustion malfunction

Diesel engine rattling

Damaged bearings Injection nozzles damaged or carbonized Piston rings worn or pistons corroded

Abnormal sounds

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Lube oil pressure too low

Lube oil in the cooling system

Leaks on the industion and exhaust lines are causing a whistling sound Scraping of the turbines or compressor wheel on the housing; Foreign bodies in compressor or turbine; bearings of rotating parts corroded to the point of siezure Oil level in oil pan too low Lube oil has too low a viscosity

Remedy Check; consult LIEBHERR AFTERSALES-SERVICE Functional or visual inspection; consult LIEBHERR AFTER-SALES-SERVICE Rectify oil level

Overhaul or replace cylinder heads, replace pistons and liners; consult LIEBHERR AFTER-SALES-SERVICE

Check exhaust turbocharger and replace if necessary; consult LIEBHERR AFTER-SALES-SERVICE Find the damaged cylinder via pressure test; consult LIEBHERR AFTERSALES-SERVICE Consult LIEBHERR AFTER-SALESSERVICE Consult LIEBHERR AFTER-SALES-SERVICE Check, adjust, and if necessary, replace the injection nozzles; consult LIEBHERR AFTER-SALES-SERVICE Check pistons and cylinder liners and replace if necessary; consult LIEBHERR AFTER-SALES-SERVICE Rectify leaks, replace seals if necessary Replace turbocharger; consult LIEBHERR AFTER-SALES-SERVICE

Fill in oil to the prescribed marking Drain oil, fill in prescribed oil Check oil pressure and replace Oil pressure gauge or pressure sensor damaged oil pressure sensor or presfaulty sure gauge; consult LIEBHERR AFTER-SALES-SERVICE Replace lube oil pressure pump; Lube oil pressure pump faulty consult LIEBHERR AFTER-SALESSERVICE Check deenergizing valve on the lube Deenergizing valve on the lube oil oil pressure pump and replace if pressure pump blocked in the open necessary; consult LIEBHERR position AFTER-SALES-SERVICE Bearing clearance too great due to Reposition or overhaul engine wear or bearings damaged Perform pressure test, replace if leaks Oil cooler or oil cooler plate leaking are determined; consult LIEBHERR AFTER-SALES-SERVICE

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Malfunctions

Operating manual

Error code tables

Error

Cause

Lube oil in the cooling system

Cylinder head seals leaking

Cooling water in the lube oil

Cylinder head seals leaking

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O-rings on the cylinder liner leaking

Remedy Replace cylinder head seals; consult LIEBHERR AFTER-SALES-SERVICE Replace cylinder head seals; consult LIEBHERR AFTER-SALES-SERVICE Replace O-rings; consult LIEBHERR AFTER-SALES-SERVICE

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5 Maintenance

5.1 Maintenance and inspection schedule Abbreviations used in this section: Bh = Operating hours BA = Operating manual SH = Service manual AFP = Authorised specialist personnel WP = Maintenance personnel

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Different terms (circuit, box – filled or circuit, box – empty) divide the maintenance tasks into two groups.

Meaning of terms: – Circuit, box – filled, means that the machine operator or the maintenance personnel must carry out the maintenance tasks at their own discretion.

The maintenance intervals are: every 10 and 50 operating hours (Bh) – Circuit, box – empty, means that the authorised specialist personnel from the LIEBHERR company or their dealers must carry out or oversee the maintenance and inspection tasks.

The maintenance intervals are: upon commissioning and every 500, 1000, 2000 operating hours (Bh)

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5-1

Maintenance

Operating manual

Maintenance and inspection schedule

Customer: ............................................... Machine type: .................... Serial No.: ..................... Oper. hours: ....................... Date ..................

Special intervals

On delivery Every 10 Every 50 Every 500 Every 1000 Every 2000

Maintenance/inspection according to operating hours

TASKS TO BE PERFORMED By maintenance personnel One-off activity Repetition interval If necessary Annually at the start of the cold season

By authorised qualified personnel One-off activity Repetition interval If necessary

Diesel engine

Checking the oil level

Visual inspection (contamination, damages)

Checking the diesel engine brake

Checking or replacing diesel engine oil: CAUTION, the specified Bh are only valid if quality of the lube oil / complication factors, see Fuel and Lubricants.

Changing the oil filter

Check batteries and cable connections.

Check ribbed V-belt.

Check suction and exhaust systems for condition and leaks.

Check / adjust diesel engine regulation.

Lubricate spur gear on the flywheel.

Checl oil pan and diesel engine console for secure sitting.

3000H

Check flame heater system.

Change the oil separator. (or at the latest every 2 years) Cylinder head

Check / adjust valve clearance 3000H

Change injection valve

3000H

Check injection valve

3000H

Adjust injection valve Cooling system

Check coolant level

Check cooling system for condition and leaks..

Change water filter.

3000H

Check anticorrosive and antifreeze, as well as the DCA 4 concentration in the coolant.

Change coolant (or at least every 2 years)

Degrease cooling system.

Decalcify and derust cooling system.

Fuel system

Check water separator on the fuel pre-filter and drain water as required.

Drain water and sediments in the fuel tank.

5-2

Check oil and fuel systems for condition and leaks.

Depending on design: Replace fuel pre-filter or change or clean pre-filter sieve element.

LIEBHERR D924 T-E/TI-E - D926 T-E/TI-E -/2000010000

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Operating manual

Maintenance Maintenance and inspection schedule

Customer: ............................................... Machine type: .................... Serial No.: ..................... Oper. hours: ....................... Date ..................

Special intervals

On delivery Every 10 Every 50 Every 500 Every 1000 Every 2000

Maintenance/inspection according to operating hours

TASKS TO BE PERFORMED By maintenance personnel One-off activity Repetition interval If necessary Annually at the start of the cold season

By authorised qualified personnel One-off activity Repetition interval If necessary

Replace fuel fine filter.(distributor injection pump)

Replace fuel fine filter.(in-line injection pump)

Bleed fuel system.

Air filter system

Air filter underpressure display.

Clean dust discharge valve of the air filter.

Change dry air filter main element (depending on maintenance display / annually)

Change dry air filter safety element (with every 3rd change of the main element / annually)

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Maintenance

Operating manual

Lubricant chart, Filling quantities

5.2 Lubricant chart, Filling quantities

5.2.1

5.2.2

Table of filling quantities Name

Medium

Dosage

Units

Diesel engine (without water cooler)

Coolant

19.5

l

Diesel engine D924 (with oil filter) depending on design

Oil

approx. 18

l

Diesel engine D926 (with oil filter) depending on design

Oil

approx. 20 25

l

Lubricant chart

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The maintenance chart serves as a summary explaining the location of the maintenance points on the diesel engine and the maintenance intervals.

For more detailed information, see the section “Maintenance and inspection chart ”, as well as the individual descriptions concerning the carrying out of maintenance tasks, see the section “maintenance tasks ”.

For more detailed information concerning the fuel and lubricants, see the section “Fuels and Lubricants ”.

For information concerning the required filling amounts, “see in the section, Filling amount chart ”.

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Operating manual

Maintenance

LMB /01 /003801 //6.2/en /Version :

Lubricant chart, Filling quantities

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Maintenance

Operating manual

Maintenance tasks

5.3 Maintenance tasks

5.3.1

Special tools for maintenance tasks

Nozzle test equipment — Special tool no. 3

No. 3

Ident no.

7361236

Term Nozzle tester

See section Check injection valve

V-belt measuring equipment-Krikit 2 — Special tool no. 9.1

Ident no.

9.1

8042829

Term V-belt test equipment Krikit 2

See section Check ribbed V-belt tension LMB /01 /003801 //6.2/en /Version :

No.

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Operating manual

Maintenance Maintenance tasks

Retraction device — Special tool no. 18

No. 18

Ident no.

0524072

Term Extraction device

See section Replace injection valve

Adapter — Special tool no. 19

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No. 19

Ident no.

0524029

Term Adapter

See section Replace injection valve

Eyelet bolt — Special tool no. 21

No. 21

Ident no.

0701650

Term Eyebolts

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See section Lifting gear

5-7

Maintenance

Operating manual

Maintenance tasks

Eyelet bolt — Special tool no. 22

No. 22

Ident no.

0701651

Term Eyebolts

See section Lifting gear

Rotator — Special tool no. 30

Ident no.

Term

30

0524045

Rotary gear

See section Check and adjust valve clearance

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No.

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Operating manual

Maintenance Maintenance tasks

5.3.2

Prepatory tasks for maintenance Before carrying out diverse maintenance tasks, the diesel engine must be brought into the maintenance position, unless expressly stated otherwise in the description.

Diverse maintenance tasks are for example: – Oil level check or oil-change.

– Filter change, as well as adjustment and repair tasks.

Safety precautions for maintenance When carrying out maintenance tasks, the safety guidelines should be thoroughly noted, see chapter on Safety guidelines Maintenance position The diesel engine is in the maintenance position when:.

– the diesel engine is positioned horizontally, – the diesel engine is switched off, – the diesel engine is cool, – the battery main switch, if available, is switched off and the main switch-key has beeen removed.

5.3.3

Maintenance tasks (daily) every 10 operating hours Ensure that: – the diesel engine is in the maintenance position – the diesel engine is warm – a collecting vessel has been positioned appropriately

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Checking the oil level

The oil dipstick and oil filler stub pipe are arranged differently depending on the circumference of the diesel engine, e.g. oil dipstick on the left or right-hand side of the engine, oil filler stub pipe located on the aggregate carrier, crank housing or on the cylinder head cover.

Example oil dipstick - Oil filler stub pipe

• •

Remove oil dipstick 1 , wipe with a cloth and reinsert.

Pull out oil dipstick once more and determine oil level.

The oil level must be between min. and max.

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Maintenance

Operating manual

Maintenance tasks

It has been determined that the oil level is too low:

•

Fill oil via oil filler stub pipe 2 (quality of oil see chapter “Fuel– and Lubricants ”).

Do not fill above the uppermost marking, max. of the oil dipstick.

• Checking coolant level

Clean oil filler cap, set onto oil filler stub pipe and tighten.

The coolant level can be viewed externally via the transparent expansion tank.

Machines with non-transparent expansion tanks: Check coolant level in filler stub pipe. The level is correct if the coolant is visible.

Procedure

Caution

Danger of scalding due to coolant being sprayed out! ! Only open the sealing cap 1 on the expansion tank after the diesel engine has cooled - the coolant temperature display on the segment field of the display unit should be in the lower third of the segment field.

Coolant expansion tank

•

To check coolant level see documentation of the machine manufacturer.

It has been determined that the coolant level is too low:

• •

Do not start diesel engine.

•

Fill in prepared coolant with 50 Vol.– % anticorrosive/antifreeze at the expansion tank only.

• • • •

Fill cooling system to the maximum.

Mount sealing cap again on expansion tank and tighten. art diesel engine and allow to run warm.

Check coolant level again, and refill if necessary.

Ensure that the coolant contains at least 50% anticorrosive/antifreeze (coolant, see the chapter “Fuel and Lubricants ”).

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Turn the sealing cap on the expansion tank anticlockwise slightly until the excess pressure can be dissipated, then open.

Operating manual

Maintenance Maintenance tasks

Checking the air filter underpressure display

Die Einbaulage und Ausführung der Luftfilterunterdruckanzeige siehe Dokumentation des Geräteherstellers.

When the maximum permissible underpressure has been reached, the mechanical air filter underpressure display on the fresh air connection of the air filter is in the red, or with electronic maintenance display, the indicator lamp lights up.

Air filter underpressure display

•

Checking the air filter underpressure display

A display in the red area has been determined or the indicator lamp is lit:

• •

Do not start diesel engine.

•

Carry out tasks in accordance with the documentation of the machine manufacturer.

Air filter- safety element should not be cleaned .

Clean or replace air filter- main element.

•

If the reset key of the air filter underpressure display is available: Following maintenance of the air filter, push in the reset key all the way and release.

The display is reset to green.

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Check/drain water separator of the fuel pre-filter.

Arrangement and configuration of the fuel pre-filter with water separator differ depending on the circumference of the diesel engine.

Fuel pre-filter with water separator.

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Maintenance

Operating manual

Maintenance tasks

Fuel pre-filter with water separator Danger

Danger of fire and explosion! ! No smoking. ! Avoid naked flames. ! Only carry out tasks to the diesel engine when it is switched off.

Draining the fuel pre-filter

•

Check the water separator of the fuel pre-filter

It has been determined that there is water in the water separator of the fuel pre-filter: Do not start diesel engine.

•

Press in the drain tap handle 1 and turn anticlockwise or loosen drain plug 2 . Drain water until fuel flows out.

•

When fuel flows out: Close drain tap 1 or tighten drain plug 2.

•

Check diesel engine for leaks via visual inspection. Slightly wet sealing points are no cause for concern.

Place a collecting vessel beneath the fuel water separator, and if necessary, connect a drainage hose.

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Visual inspection (contamination, damages)

• •

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Operating manual

Maintenance Maintenance tasks

Should more serious leaks with constant oil loss or a damaged oil separator be determined: A damaged oil separator, e.g. indented cover, leaking oil vapour at the membrane vent 1 can impede functionality.

Oil separator

5.3.4

•

Replace separator, rectify any leaks immediately.

• •

Check lines and hoses for leaks via visual inspection.

Check lines and hoses for damage, wear-free arrangement and secure fixing.

Maintenance duties (weekly) every 50 operating hours The daily maintenance tasks must be performed before carrying out the weekly maintenance.

See section, “Maintenance Duties (daily) every 10 operating hours ”.

Ensure that: – the diesel engine is in the maintenance position

Draining water and sediments from the fuel tank

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Danger

Ensure the highest possible standard of cleanliness.

Danger of fire and explosion! ! No smoking. ! Avoid naked flames. ! Only carry out tasks to the diesel engine when it is switched off.

• •

Do not drain fuel onto the ground, use a suitable collecting vessel.

•

When refuelling, keep the fuel level as high as possible in the tank, in order that condensation is avoided as much as possible.

For draining water and sediment from the fuel tank, see “Manufacturer's Machine Documentation ”.

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Maintenance

Operating manual

Maintenance tasks

Cleaning the dust extraction valve of the air filter

Maintenance of the air filter is not necessary if it is displayed via the maintenance display on the air filter or via an indicator lamp for filter maintenance, for example.

Important: A damaged or hardened dust extraction valve renders functioning of the service cover ineffective, and this in turn leads to shorter life-expectancy of the filter element.

•

Press the rubber lip on the dust extraction valve in order to drain the service cover.

•

Clean dust extraction valve regularly when working in extremely dusty conditions.

The dust extraction valve is damaged or remains open:

•

5.3.5

Replace dust extraction valve.

Maintenance tasks every 500 operating hours Before carrying out the 500 operating hours maintenance: – the daily maintenance tasks, see the section “Maintenance Tasks (daily) every 10 operating hours ”are to be carried out.

– the weekly maintenance tasks, see the section “Maintenance Tasks (weekly) every 50 operating hours ”are to be carried out.

Ensure that: – the diesel engine is in the maintenance position The diesel engine brakes are mounted on either side of the turbocharger.

Diesel engine brake – Flap

• •

Check and oil pivot of the operating cylinder.

Actuate brake flap.

Ensure that the flap returns soundly to the start position following actuation.

This can be recognised on the exterior of the brake flap shaft, see arrow (fig. diesel engine brake – flap). The groove must be positioned parallel to the exhaust pipe.

If the flap remains where it is, the diesel engine becomes overheated, fuel consumption is increased and the exhaust is thick smoke.

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Checking the diesel engine brake

Operating manual

Maintenance Maintenance tasks

Checking the cooling sysem for leaks and condition

•

Check cooler, coolant pump and heat exchanger for the heating system for leaks.

•

Check all lines and hoses of the cooling and heating systems for leaks, damage, wear-free arrangement and secure fixing.

•

Do not allow the discs to become clogged with dirt.

Check cooler for exterior contamination.

Leaks have been determined in the cooling system:

• • Changing the water filter

o not start diesel engine.

Determine and remedy cause.

The water filter is mounted on front of the diesel engine on the thermostat housing.

The water filter contains an anticorrosive additive, which takes care of the anticorrosive characteristics of the cooling system.

Ensure that: – A water filter cartridge is already on hand.

Water filter

• • • •

Close the shut-off valve 1 on the filter housing.

•

Tighten filter element from ½ - ¾ of a turn. (Do not use any tools for tightening).

•

Open shut-off valve 1 again (ON).

Unscrew filter element 2 .

Lightly oil sealing ring on the new filter element.

LMB /01 /003801 //6.2/en /Version :

Screw on new filter element until the sealing ring is resting on the filter head When the sealing ring is resting on the filter head

Checking anticorrosive and antifreeze, as well as DCA 4 concentration in the coolant

n order that an ideal anticorrosive/antifreeze mixture be guaranteed, the coolant should be checked for effectivenes.

A coolant strip-test kit is a simple, but effective method, to test the freezing point and additive content (DCA 4).

•

Take a sample of the coolant and analyse with the coolant strip-test kit.

Should the analysis indicate too low an antifreeze content or too low a DCA 4 concentration, the mix ratio is to be modified, see the section, Fuel and Lubricants.

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Maintenance

Operating manual

Maintenance tasks

Checking oil and fuel systems for leaks and condition

•

Check oil pan, oil filter, injection pump and fuel filter for leaks.

•

Check all lines and hoses of the oil and fuel systems for leaks, damage, wear-free arrangement and secure fixing.

Leaks have been determined on the oil and fuel systems:

• • Changing the diesel engine oil

Do not start diesel engine.

Determine and remedy cause, replace damaged parts .

The oil drain valve is located below the diesel engine on the oil pan.

Ensure that: – The diesel engine is positioned horizontally – The diesel engine is switched off – The diesel engine is warm – A suitable container with approx. 26 l volumetric capacity, an oil drainage hose and the diesel engine oil, in accordance with oil specifications, are already on-hand.

Drain valve with drainage hose Unscrew sealing cap on the oil pan's oil drain valve.

Screw oil drainage hose to the oil drain valve. Öl in den bereitgestellten Behälter ablaufen lassen.

Unscrew oil drainage hose and screw on sealing cap on the oil drain valve.

LMB /01 /003801 //6.2/en /Version :

• • • •

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Operating manual

Maintenance Maintenance tasks

Diesel engine oil filler stub pipe

•

Fill in oil via the oil filler stub pipe 2 to between the min. and max. markings on the oil dipstick 1 .

• • •

Clean the oil filler cap, mount onto the oil filler stub pipe and tighten.

Start the diesel engine and check the oil pressure.

Switch off diesel engine and check the oil level after 2 - 3 minutes with the dipstick.

The oil level is no longer between the min. and max. markings?

•

LMB /01 /003801 //6.2/en /Version :

Replacing the oil filter

Correct oil level.

Depending on the circumference of the diesel engine, the oil filter is mounted either fixed or suspended on the right-hand side of the diesel engine or remotely mounted on the diesel engine.

Ensure that: – a retaining wrench, a suitable container and original LIEBHERR oil filter cartridges (2 x) are already on-hand.

Oil filter

• •

Position a suitable container below the diesel engine.

•

Clean the sealing surfaces of the filter console.

Loosen oil filter cartridge 1 using a retaining wrench and unscrew the filter.

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Maintenance

Operating manual

Maintenance tasks

The old filter seal and its remnants must all be completely removed.

•

Coat rubber sealing ring on the new oil filter cartridge thinly with diesel engine oil.

•

Screw on new oil filter cartridge until the sealing ring is resting on the filter console.

If the sealing ring is resting on the filter console:

•

Tighten oil filter cartridge around ½ - ¾ of a turn (do not use any tools for tightening).

• •

Start the diesel engine.

• •

Shut down diesel engine.

Check oil pressure (display unit diesel engine oil pressure) and seals on the oil filter.

Check oil level after 2 - 3 minutes via the dipstick.

The oil level is not between the min. and max. markings?

• Checking condition of ribbed V-belt

Correct oil level

The ribbed V-belt is at the front of the diesel engine, and depending on the circumference of the diesel engine, run of the ribbed V-belt may differ, e.g. with generator and generator drive with compressor.

Ensure that: – A ratchet DIN 3122 D 12,5 (1/2 „) as well as new ribbed V-belt are alreayd on-hand.

Damage to the ribbed V-belt includes: – Rib breaks – Transversal fractures in several ribs – Rubber nodules in the base of the belt.

– Deposition of contamination or stones.

– Ribs loosened from base of belt.

– Transversal fractures on the rear side.

Check ribbed V-belt for damage.

LMB /01 /003801 //6.2/en /Version :

•

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Operating manual

Maintenance Maintenance tasks

Damage has been determined?

•

Replace ribbed V-belt

Ribbed V-belts generator and generator drive with compressor

• •

Loosen screws 1 .

Turn tensioning pulley 2 or (configuration B) tensioning pulley 3 and 4 clockwise using a wrench or (configuration A) anticlockwise, ease tension from and dismantle ribbed V-belt.

•

LMB /01 /003801 //6.2/en /Version :

Check tensioning pulley and belt discs for sound condition (e.g. struck bearing from tensioning pulley, as well as wear of belt disc profile).

If parts are damaged, replace the parts.

• •

Mount new ribbed V-belt onto all belt discs and tensioning pulleys.

•

Adjust ribbed V-belt tension Turn tensioning pulley 2 or tensioning pulley 4 (configuration B) anticlockwise using a ratchet (configuration A) until the correct ribbed V-belt tension has been reached and tighten screw 1.

•

Allow to run after 10 to15 minutes.

Check tension and tighten if necessary.

If available, pre-set tensioning pulley 3 (configuration A and B) 45° as represented and tighten screw 1.

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Maintenance

Operating manual

Maintenance tasks

Keilrippenriemen Spannung prüfen

Test point: in the centre between KW belt disc –generator belt disc or in the centre between tensioning pulley 3 and belt disc from the compressor see arrow, fig. “ribbed V-belt generator and generator drive with compressor ”).

Ensure that: – measuring equipment “Krikit 2 ” (special tool no. 9.1) is on-hand.

Measured values for checking the tension manually are: – Ribbed V-belt pre-tension: 120 N – Indentation depth: 13 mm

•

Check tension of the ribbed V-belt at the test points.

Should the pre-entered measured values not be reached?

• •

Apply or relieve tension in the ribbed V-belt.

•

Test point between tensioning pulley 3 and belt disc from the compressor.

Loosen tensioning pulley 3 and turn anticlockwise with a ratchet, or clockwise until the correct ribbed V-belt tension has been reached and tighten.

Test point between KW belt disc and generator belt disc.

Loosen tensioning pulley 2 or tensioning pulley 4 and turn anticlockwise using a ratchet, or clockwise until the correct V-belt tension has been reached and tighten.

V-belt 8 gooves, width approx. 28 mm

New ribbed V-belt KG scale

Used ribbed V-belt KG scale

50

40 to 50

Measuring equipment Krikit 2 (special tool no. 9.1)

5 - 20

•

With measuring equipment Krikit 2 (special tool no. 9.1) Lower display arm A ompletely into the measuring equipment.

•

Set measuring equipment on the measuring point on the top of the ribbed V-belt.

LIEBHERR D924 T-E/TI-E - D926 T-E/TI-E -/2000010000

LMB /01 /003801 //6.2/en /Version :

Measured values for checking the tension with measuring equipment “Krikit 2 ”(special tool no. 9.1) are:

Operating manual

Maintenance Maintenance tasks

•

Slowly apply pressure evenly to the ribbed V-belt using the push-button until the pressure spring can be felt and heard snapping in.

The display arm now shows the ribbed V-belt pressure.

•

Lift measuring equipment carefully and read measured value from the intersection of the “KG ” scale and the display arm (see arrow).

Does the value which has been read not match the table?

Checking batteries and cable connections

• •

Apply or relieve tension of ribbed V-belt.

•

Test point between tensioning pulley 3 and belt disc from the compressor.

Loosen tensioning pulley 3 and turn anticlockwise using a ratchet, or clockwise until correct tension of the ribbed V-belt has been reached.

•

Only use completely charged, fully maintained batteries.

Maintenance, see machine manufacturer documentation.

• •

Coat the terminal with acid protection grease (terminal grease).

Test point between KW belt disc and generator belt disc.

Loosen tensioning pulley 2 or tensioning pulley 4 anticlockwise using a ratchet, or clockwise until the correct ribbed V-belt tension has been reached.

Check all electrical lines for damage, wear-free arrangement and secure fixing.

Damaged lines have been determined?

Replace faulty lines or cable harnesses.

5.3.6

Maintenance tasks every 1000 operating hours Before carrying out the maintenance tasks after 1000 operating hours, first: – carry out the daily maintenance tasks, see the section “maintenance tasks (daily) every 10 operating hours ”.

– carry out the weekly maintenance tasks, see the section “maintenance tasks (weekly) every 50 operating hours ”.

– carry out the 500 hour maintenance tasks, see the section “maintenance tasks after 500 operating hours ”.

Diesel engine

LMB /01 /003801 //6.2/en /Version :

Checking and adjusting diesel engine regulation

Ensure that: – the documentation of the machine manufacturer is on-hand.

•

Check or adjust diesel engine regulation in accordance with the machine manufacturer documentation.

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Maintenance

Operating manual

Maintenance tasks

Lubricating the spur gear on the flywheel.

The maintenance cover is on the right-hand side of the diesel engine on the flywheel housing.

Ensure that: – the diesel engine is in the maintenance position.

Maintenance cover on the flywheel.

Checking oil pan and diesel engine console for secure sitting.

• •

Unscrew maintenance cover 1 from the flywheel housing.

•

Screw on maintenance cover again.

Ensure that: – The diesel engine is in the maintenance position.

• •

Check oil pan for secure sitting and tighten screws if necessary.

Check diesel engine consoles for secure sitting and tighten screws if necessary.

Ensure that: – The diesel engine is in the maintenance position.

•

Check suction lines between air filter and diesel engine for condition, for leaks and secure sitting.

•

Check exhaust lines for condition, leaks and secure sitting.

LMB /01 /003801 //6.2/en /Version :

Checking suction and exhaust systems for condition and for leaks.

Do not overlubricate spur gear, speed sensors become smeared and malfunction.

Check spur gear and if necessary, lubricate lightly with standard grease.

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Operating manual

Maintenance Maintenance tasks

Cylinder head valve Preparation for checking and adjusting valve clearance.

Ensure that: – The diesel engine is in the maintenance position.

– The diesel engine has cooled, – Special tool no. 30 is on-hand.

– New seals for the cylinder head screws are already standing ready.

Only carry out the inspection with the diesel engine cooled, for adjustmen values see “Technical Data ” valve clearance.

Note: – Cylinder 1 is located on the flywheel side.

– Direction of roation left as facing the flywheel.

– Exhaust valve of the respective cylinder is on the flywheel side.

Rotary gear — Valve overlapping

•

Remove cylinder head covers, mount rotary gear, special tool no. 40, on the flywheel housing.

•

LMB /01 /003801 //6.2/en /Version :

Turn crankshaft in direction of rotation until the cylinder to be adjusted overlaps the valve positioned opposite.

See table for details.

Valves of the cylinder

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Maintenance

Operating manual

Maintenance tasks

Overlap Adjust Overlap Adjust Checking valve clearance and adjusting the Standart

Valve of cylinder D926 6 2 1 5 Valve of cylinder D924 4 2 1 3

4 3

1 6

1 4

3 2

5 2

3 4

Checking and adjusting valve clearance:

Checking and adjusting valve clearance.

•

Insert a feeler gauge between the valve and the tipping lever, and check the valve clearance.

The clearance does not match the adjustment values, see “Technical Data ” Ventilspiel überein?

•

Loosen lock nut on the adjustment screw of the respective tipping lever and correct the adjustment.

•

Tighten lock nut.

• •

Check adjustment again.

•

Dismantle rotary gear.

LMB /01 /003801 //6.2/en /Version :

After checking or adjusting all valves, mount the cylinder head covers with new seals.

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Operating manual

Maintenance Maintenance tasks

Checking valve clearance and adjusting the engine auxiliary brake system (ZBS)

Checking the inlet valves

Checking the inlet valves

•

Insert feeler gauge between valve and tipping lever and check, or if necessary adjust, the valve clearance.

Checking the outlet valves:

Checking the outlet valves

•

Push the tipping lever onto the valve beside the piston 5 several times until oil is no longer flowing from the relief boreole 6 .

Has the oil been pushed completely from the piston chamber?

Insert feeler gauge between exhaust valve and piston valve clearance and adjust if necessary.

5 and check

LMB /01 /003801 //6.2/en /Version :

•

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Maintenance

Operating manual

Maintenance tasks

Adjusting the inlet valve:

Adjusting the inlet valve

•

Loosen the lock nut on the adjustment screw of the respective tipping lever and adjust the setting.

• •

Tighten lock nut again.

Check adjustment again after tightening the lock nut.

Adjusting the outlet valve:

Adjusting tthe outlet valve

5 - 26

•

Loosen lock nut 2 and unscrew adjustment screw possible without forcing.

•

Loosen lock nut 4 and turn back adjustment screw 3 until the 0.50 mm feeler gauge can be inserted between the piston 5 and the valve.

•

Screw in adjustment screw 3 until the feeler gauge jams, the piston 5 is pushed back.

• •

Adjust valve clearance to 0.50 mm on the adjustment screw 3 .

as far as

Tighten lock nut 4 .

LIEBHERR D924 T-E/TI-E - D926 T-E/TI-E -/2000010000

LMB /01 /003801 //6.2/en /Version :

1

Operating manual

Maintenance Maintenance tasks

Adjusting the outlet valve.

• •

Insert 0.30 mm feeler gauge between piston 5 and valve.

•

Hold piston 5 pressed down and screw in adjustment screw 1 until the valve clearance has been set.

Push tipping lever onto the valve via a screwdriver in the area of the piston 5 until the Kolben 5 hits the stop.

Has the oil been pushed completely from the piston chamber?

•

Tighten lock nut 2 .

Note: Following successful adjustment, turn to the tappet rod where clearance must be resulted.

• •

After adjusting all valves, mount cylinder head covers with new seals Dismantle rotary gear.

Flame-heater system Checking the flame-heater system

Danger

Arrangement and design of the flame-heater system differ depending on circumference of the diesel engine.

Ensure that: – a collecting vessel is on-hand for the fuel.

Danger of fire and explosion! ! No smoking. ! Avoid naked flames. ! Only work on the diesel engine when engine is switched off.

Position collecting vessel below thediesel engine.

LMB /01 /003801 //6.2/en /Version :

•

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Maintenance

Operating manual

Maintenance tasks

Checking the solenoid valve:

Glow plug — Solenoid valve

• • •

Unscrew fuel line to the glow plug.

Position shut-off lever on the injection pump to Stop.

Turn over the diesel engine via the starter.

Fuel flows from the fuel line.

•

Position shut-off lever on the injection pump from Stop into the standard position and start the diesel engine.

Fuel supply to the fuel line is stopped.

Should no fuel be supplied when turning over the diesel engine, or if fuel supply does not stop when the diesel engine is already running!

•

Replace the solenoid valve, when changing note the throughflow direction, indicated via an arrow.

Checking the glow plug.

• •

Remove glow plug and connect to fuel line or electrical line.

Position shut-off lever on the injection pump to Stop and preheat.

Glow plug starts glowing red on the coiled filament after preheating is completed.

•

Turn over the diesel engine via the starter. ll arriving fuel is vapourised on the glowing coiled filament

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LMB /01 /003801 //6.2/en /Version :

Checking the glow plug:

Operating manual

Maintenance Maintenance tasks

Should the coiled filament on the glow plug not start glowing, or should no fuel be supplied to the coiled filament when the diesel engine is turned over!

•

Replacing the glow plug.

Removing the glow plug:

Removing glow plugs — Installing glow plugs.

• •

Disconnect electrical line and fuel line.

•

Coat thread of glow plug with sealing compound, Hylomar SQ 32 M, Omnivisic 1050 or Reinzoplast, and in screw into the suction pipe.

• •

Connect and tighten fuel line.

Loosen lock nut and unscrew glow plug from the suction pipe.

Installing the glow plug:

Tighten lock nut on the glow plug and connect electrical line.

Fuel prefilter Preparation for replacing the fuel prefilter.

LMB /01 /003801 //6.2/en /Version :

Danger

Arrangement and design of the fuel prefilter with water separator differ depending on circemference of the diesel engine.

Ensure that the following are on-hand: – A collecting vessel for the fuel.

– An original Liebherr filter cartridge or filter element.

Danger of fire and explosion! ! No smoking. ! Avoid naked flames. ! Only work on the diesel engine when engine is switched off.

•

If a fuel shut-off tap is available: Close fuel shut-off tap.

• •

Position collecting vessel below the fuel prefilter.

Clean fuel prefilter and surrounding area carefully.

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Maintenance

Operating manual

Maintenance tasks

Variant I — Replacing the fuel pre-filter.

Replacing the fuel pre-filter.

• • • • •

Drain fuel: Unscrew vent screw 1 and drain plug 2 .

• •

Unscrew water separator container on the filter cartridge.

•

If the filter base is contaminatedt: Clean the filter base.

•

Lubricate sealing rings 6 of the new filter cartridge with uncontaminated fuel. Screw on new filter cartridge to the filter base and tighten by hand.

• •

Open fuel shut-off tap and aerate the fuel prefilter.

Loosen filter cartridge 3 via belt key or similar tool and unscrew.

Unscrew water separator container 4 from the filter cartridge.

Disposing of the old filter cartridge.

Wash water separator container with water and dry using compressed air.

Check filter base for cleanliness and ensure that the thread adapter 5 is sitting securely in the filter base.

Close vent screw.

Changing the fuel prefilter

• •

5 - 30

Drain fuel:Unscrew drain plug 1 .

Push locking ring 2 upwards and turn anticlockwise around 1/4 of a turn.

LIEBHERR D924 T-E/TI-E - D926 T-E/TI-E -/2000010000

LMB /01 /003801 //6.2/en /Version :

Variant II — Replacing the fuel prefilter

Operating manual

Maintenance Maintenance tasks

• • • •

Pull away filter element 3 with locking ring (2) downwards.

• • •

Unscrew water separator container on the filter element.

•

Mount the new filter element onto the filter base. Ensure that the slot of the filter base and cam of the filter element correspond.

Unscrew water separator container 4 from the filter element Disposing of the old filter element Wash water separator container with water and dry using compressed air.

Check filter base for cleanliness.

If the filter base is contaminated: Clean the filter base.

•

Tighten locking ring manually in a clockwise direction around 1/3 of a rurn.

The locking ring snaps into the groove with a click.

•

Open fuel shut-off tap and aerate fuel prefilter

Variant III — Cleaning and replacing the fuel prefilter filter element.

LMB /01 /003801 //6.2/en /Version :

Fuel prefilter.

• • •

Press in drain tap lever 1 and turn anticlockwise, drain fuel.

•

Dispose of paper filter element 5 or clean or replace sieve element 6 .

• • •

Reinsert new paper filter 5 or cleaned sieve element 6 .

Unscrew screws 2 and remove cover 3 with sealing 4 .

Remove paper filter element 5 spring cassette 7 .

or sieve element 6

with complete

Check sealing 4 and replace if necessary, reassemble in reverse order.

Open fuel shut-off tap and aerate fuel prefilter.

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Maintenance

Operating manual

Maintenance tasks

5.3.7

Maintenance tasks every 2000 operating hours.

Before carrying out the 2000 operating hours maintenance tasks, first carry out: – the daily maintenance tasks, see in the section “Mainteannce tasks (daily) every 10 operating hours ”.

– the weekly maintenance tasks, see in the section “Maintenance tasks (weekly) every 50 operating hours, ”.

– the 500 operating hours maintenance tasks, see in the section “Maintenance tasks every 500 operating hours ”.

– the 1000 operating hours maintenance tasks, see in the section “Maintenance tasks every 1000 operating hours ”

Fuel fine filter.

Preparation for replacing the fuel fine filter.

Danger

Arrangement and design of the fuel fine filter differ depending on circumference of the diesel engine.

Ensure that the following are on-hand: – A collecting vessel for the fuel.

– An original Liebherr filter cartridge.

Danger of fire and explosion! ! No smoking. ! Avoid naked flames. ! Only work on the diesel engine when engine is switched off.

•

If a fuel shut-off tap is available: Close fuel shut-off tap.

• •

Position collecting vessel below fuel fine filter.

Clean fuel fine filter and surrounding area carefully.

Replacing the fuel fine filter.

• • •

5 - 32

Loosen filter cartridge 1 with belt key or similar tool and unscrew.

Dispose of old filter cartridge.

Check filter base for cleanliness and ensure that the thread adapter 2 is sitting securely in the filter base.

LIEBHERR D924 T-E/TI-E - D926 T-E/TI-E -/2000010000

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Variant I — Replacing the fuel fine filter.

Operating manual

Maintenance Maintenance tasks

•

If the filter base is contaminated: Clean the filter base.

•

Lubricate sealing rings 3 of the new filter cartridge with uncontaminated fuel. Screw on new filter cartridge to the filter base and tighten by hand.

•

Open fuel shut-off tap and aerate the fuel fine filter.

Variant II — Replacing the fuel fine filter.

Replacing the fuel fine filter.

• •

DRain fuel:Oen drain plug 1 .

• • • •

Pull away filter element 3 downwards with locking ring (2) .

•

Mount new filter element onto filter base. Ensure that the slot of the filter base and cam of the filter element correspond.

Push locking ring 2 upwards and turn anticlockwise around 1/4 of a turn.

Dispose of old filter element.

Check filter base for cleanliness.

If the filter base is contaminated: Clean the filter base.

•

Tighten locking ring manually in a clockwise direction around 1/3 of a turn.

The locking ring snaps into the groove with a click.

Open fuel shut-off tap and aerate the fuel fine filter.

LMB /01 /003801 //6.2/en /Version :

•

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Maintenance

Operating manual

Maintenance tasks

5.3.8

Maintenance tasks every 3000 operating hours.

VBefore carrying out the 3000 operating hours maintenance tasks, first carry out: – the daily maintenance tasks, see in the section “Maintenance tasks (daily) every 10 operating hours, ”.

– the weekly maintenance tasks, see in the section “Maintenance tasks (weekly) every 50 operating hours, ”.

– the 500 operating hours maintenance tasks, see in the section “Maintenance tasks every 500 operating hours ”.

– the1000 operating hours maintenance tasks, see in the section “Maintenance tasks every 1000 operating hours ” – the 2000 operating ours maintenance tasks, see in the section “Maintenance tasks every 2000 operating hours ”.

Cylinder head injection valve.

Replacing the injection valve.

Ensure that the following are on-hand: – Special tool no. 18 – Special tool no. 19 Dismantling:

Injection line — Leak oil collection line Dismantling the injection line on the injection valve.

Dismantling the leak oil collection line on the injection valve.

Injection valve mounting — Injection valve

• • •

5 - 34

Loosen and unscrew screws on the injection valve mounting.

Remove injection valve mounting and spacer sleeve Loosen injection valve by turning with a spanner in the cylinder head.

LIEBHERR D924 T-E/TI-E - D926 T-E/TI-E -/2000010000

LMB /01 /003801 //6.2/en /Version :

• •

Operating manual

Maintenance Maintenance tasks

Extraction device — Sealing washer

•

Fit extraction device, special tool no. 18 with adapter, special tool no.

19, .

• • •

Screw on extraction devive to the injection valve.

Remove injection valve from the cylinder head by striking.

Remove sealing washer from the injection valve.

Is the sealing ring still in the cylinder head?

•

Remove sealing washer using a bent steel wire.

•

Check and adjust injection valve, see “section, Checking or adjusting the injection valve ”.

Installation:

LMB /01 /003801 //6.2/en /Version :

Installation — Injection valve

• • • • •

Fit injection valve with new O-ring.

Fasten new sealing washer with grease on the injection valve.

Lubricate injection valve on the shaft with grease.

Insert injection valve into the borehole..

Tightening specification, see Technical Data.

Mount spacer sleeve and injection valve mounting and tighten using the screws.

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Maintenance

Operating manual

Maintenance tasks

Caution: The leak oil connetions on the injection valves must be pointing to the side of the injection pumps.

• • Checking the injection valve.

Mount leak oil collection line with new seals.

Tighten injection lines.

Ensure that the following are on-hand: – Special tool no. 3 – Spray-pressure value see “Technical Data ”.

– Injection valve disassemled, see section “Replacing the injection valve ”.

Check:

Nozzle tester- special tool no. 3

• •

Remove carbon residues carefully from the nozzles.

Mount injection valve to the nozzle tester special tool no 3.

To check, only use filtered diesel fuel or uncontaminated test oil.

Danger of injury when checking due to a spraying jet!

The jet penetrates deeply into the skin and damages the tissue.

Fuel which penetrates the blood stream can cause blood poisoning. ! Ensure when checking that the hands do not come into contact with spraying jets.

Nozzle tester switched off — Nozzle tester switched on

•

5 - 36

With the pressure gauge switched off, actuate the nozzle tester quickly a few times, whilst observing the spray screen.

LIEBHERR D924 T-E/TI-E - D926 T-E/TI-E -/2000010000

LMB /01 /003801 //6.2/en /Version :

Warning

Operating manual

Maintenance Maintenance tasks

The injection nozzles must be heard to snap in and at the same time, fine, vapourised beams must form without plumes at the side.

Adjusting the injection valve.

• •

Switch on the pressure gauge.

•

Read the spray pressure on the pressure gauge and compare with the specified values in the technical data.

The nozzle may not be allowed to drip if 25–30 below the prescribed spray pressure value.

Push down the lever of the nozzle tester slowly until the nozzle begins spraying.

Ensure that the following are on-hand: – Injection valve dismanteled, see section “Replacing the injection valve ”.

Adjusting spray pressure

Fixing the injection valve — Removing the pressure spring

• •

Fixing the injection valve and dismantling the injection valve.

LMB /01 /003801 //6.2/en /Version :

Remove pressure spring and add or remove pressure adjustment washers as required.

The spray pressure increases as washers are added and decreases as washers are removed.

Dismantling the injection nozzle:

Dismantling the injection nozzle

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Maintenance

Operating manual

Maintenance tasks

• •

Unscrew the nozzle adjusting nut 1 .

•

Clean nozzel pin 7 and nozzle casing 8 in uncontaminated fuel and check via drop test.

Remove injection nozzle 2 , clearance washer with fixing pin 3 , thrust pin 4 , pressure spring 5 and pressure adjustment washers 6 from the nozzle holder.

With the nozzle casing fixed in a vertical position, the nozzle pin is not gliding slowly and smoothly into the nozzle casing under its own weight?

•

Replace the nozzle casing.

•

Clean the other parts.

Installing the injection nozzle:

Installing the injection nozzle Insert or plug in pressure adjustment screws, pressure sping, thrust pin, clearance washers with fixing pin and injection nozzle into the nozzle holder.

•

Tightening specifications, see “Technical Data ”.

Screw on and tighten nozzle adjusting nut.

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Operating manual

Maintenance Maintenance tasks

Cooling system Changing the coolant

Ensure that: – The diesel engine is in the maintenance position.

– The diesel engine has cooled down.

– The heating taps are open if available.

– A collecting vessel and coolant with DCA 4, mix ratio, see “Fuel and lubricants ”, filling amounts see “Machine manufacturer documentation ”.

Draining the coolant:

Draining the coolant

•

Avoid opening of the sealing cap 1 while the diesel engine is still warm.

•

Turn the sealing cap anticlockwise slightly until excess pressure can be dissipated, then open.

• •

Position a container below the diesel engine

• •

Open the drain plug on the coolant pump

on the coolant expansion tank

Open the drain plug 2 on the oil cooler housing on the right-hand side of the diesel engine.

Open the drain plug on the cooler (see machine manufacturer's documentation).

Coolant from the oil cooler housing, the coolant pump and the cooler flows into the container.

•

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If the coolant has been drained completely from the cooling system.

Close drain plug on the oil cooler housing, coolant pump and cooler again.

Filling coolant:

•

Only fill in prepared coolant with 50 Vol.– % anticorrosive/ antifreeze and DCA 4 on the colant expansion tank.

• • • •

Fill cooling system to Maximum.

Mount and close sealing cap on the expansion tank.

Start diesel engine and run until warm.

Check coolant level again and refill if necessary.

Ensure that the coolant contains at least 50 Vol.–% anticorrosive/ antifreeze and DCA 4.

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Maintenance

Operating manual

Maintenance tasks

Replacing the oil separator.

Ensure that: – The diesel engine is in the maintenance position.

– an oil separator with new O-ring is at-hand.

Dismantling the oil separator:

Dismantling — Installation

• •

Loosen hose collars 1 and push hose 2 from the oil separator.

• •

Install new O-ring in the oil separator.

•

Mount fixing, push on hose and tighten hose collars.

Loosen fastening collars 3 and remove oil separator.

Installing the oil separator:

5.3.9

Puish oil separator onto a pipe or support in the aggregate carrier and tighten the fastening collars.

Maintenance tasks as required.

Dray air filter.

Ensure that: – The diesel engine is in the maintenance position.

Replacing the dry air filter main element.

The dry air filter differs depending on the design of the machine.

Should contamination of the air filter still be indicated following maintenance of the main element, the safety element must also be replaced.

Replacing the dray air filter safety element.

The safety element should only be replaced after every third change of the main element, howerver at least once a year .

•

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Replacemen of the main element, see “Machine manufacturer's documentation ”.

Replacement of the safety element, see “Machine manufacturer's documentation ”.

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Operating manual

Maintenance Maintenance tasks

Fuel system, Preparation for bleeding the fuel system.

Danger

It is necessary to bleed the fuel system following: – Changing of the fuel filter.

– Cleaning of the fuel tank.

– Repairs to the fuel system.

– The fuel tank running empty.

Ensure that: – The diesel engine is in the maintenance position.

– A collecting vessel is on-hand to catch he fuel.

Danger of fire and explosion! ! No smoking. ! Avoid naked flames. ! Only work on the diesel engine when the engine is switched off.

•

Open the shut-off valve on the fuel container if available.

Bleeding the fuel system.(in-line injection pump

Bleeding the fuel system (in-line injection pump)

•

Loosen vent screw 1 on the filter head and unscrew around 2 or 3 turns

•

Actuate hand pump 2 Bubble-free fuel is flowing from the vent screw!

• • •

Tighten vent screw 1 again

• • •

Tighten fuel line 3 again.

•

Tighten excess current valve 5 and leak oil return line 4 again.

Loosen fuel line 3 on the injection pump

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Actuate hand pump 2 .

Bubble-free fuel is flowing from the fuel line!

Loosen leak oil return line 4 with excess current valve 5 .

Actuate hand pump 2 .

Bubble-free fuel is flowing out!

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Maintenance

Operating manual

Maintenance tasks

Injection valve

• •

Loosen swivel nut of the injection line on the injection valves

• •

Tighten swivel nuts again

Actuate starter Bubble-free fuel is flowing out!

Start diesel engine and check seals of the connections

The diesel engine will not run on after starting?

•

Repeat bleed process.

Bleeding the fuel system.(distributor injection pump)

•

Loosen the vent screw 1 on the fuel fine filter and unscrew around 2 or 3 turns.

•

Actuate lever on the fuel conveyor pump 2 .

Bubble-free fuel is flowing from the vent screw!

•

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Tighten vent screw 1 again.

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Fuel fine filter — Fuel conveyor pump

Operating manual

Maintenance Maintenance tasks

Fuel return line — Injection line

• •

Loosen fuel return line 3 to the tank on the injection pump

• • •

Tighten fuel return line 3 again.

• •

Tighten swivel nuts 4 again.

Actuate lever on the fuel conveyor pump 2 .

Bubble-free fuel is flowing from the fuel line!

Loosen swivel nuts of the injection lines on the injection valves.

Actuate starter Bubble-free fuel flows out!

Start diesel engine and check seals of the connection.

The diesel engine will not run on after starting?

Repeat bleed process.

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Maintenance

Operating manual

Maintenance tasks

Cooling system.

Lubricating the cooling system.

Lubrication of the cooling system is necessary if leaks are discovered in: – cylinder head seals, – oil cooler seals, – oil cooler and oil cooler plate. diesel engine oil has been directed into the cooling water circuit.

After rectifying damages, the coolant system must be lubricated before refilling coolant.

Ensure that: – The diesel engine is in the maintenance position.

– Maintenance task “draining coolant ”has been carried out.

– A degreasing agent, 5% aqueous solution of P3 Standard or P3T 5124, from the Henkel company is already on-hand and the instructions of the manufacturer are adhered to.

– eiA sealing for the thermostat housing is on-hand.

– A collecting vessel and coolant with DCA 4, mix ratio see “Fuel and lubricants ”, filling amount see “machine manufacturer documentation ”is on-hand.

•

Dismantle both coolant thermostats, block in the open position and reinstall.

• •

Fill cooling system wih a mixture of water and 5% degreasing agent.

• •

Maintain this diesel engine temperature for approx. 5 minutes.

Warm up diesel engine with heating switched on and a coolant temperature of 90° C.

Switch off diesel engine and allow to cool to approx. 50° C. If the cooling system has cooled to approx. 50° C.

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Danger of scalding due to degreasing or derusting agent spraying out! ! Only open sealing cap on the expansion tank when the diesel engine has cooled - the coolant temperature display on the segment field should be in the lower third of the segment field.

• • •

Drain degreasing agent.

•

Drain scavenging water, refill cooling system with fresh water and repeat scavenging procedure.

•

Dismantle coolant thermostats, manoeuvre into standard position and install with new thermostat housing sealing.

•

Carry out maintenance task “fill coolant ”.

Fill cooling system with fresh water.

Allow diesel engine to run for approx. 5 minutes for scavenging purposes.

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Caution

Operating manual

Maintenance Maintenance tasks

Decalcifying and derusting the cooling system.

Decalcifying and derusting of the cooling system is necessary after filling with: – coolant not prescribed, – coolant with too low a mix ratio.

A coolant not prescribed can cause sedimentaion or even corrosion in the cooling system.

These sedimentations can then lead to leaks in the coolant pumps or imperfect cooling output due to the additional interior cooler.

Ensure that: – The diesel engine is in the maintenance position.

– The maintenance task “drain coolant ”has been carried out.

– A decalcifying or degreasing agent: 10% aqueous soultion of lemon—, wine or oxalic acid, determined by your chemical dealer, is already on-hand.

– A sealing for the thermostat housing is on-hand.

– A collecting vessel and coolant with DCA 4, mix ratio see “Fuel and lubricants ”, filling amount see “machine manufacturer documentation ”is on-hand.

•

Dismantle both coolant thermostats, block in the open position and reinstall.

•

Fill cooling system completely with a mixture of water and 10% degreasing or derusting agent.

•

Warm up diesel engine with heating switched on and a coolant temperature of 90° C.

• •

Maintain this diesel engine temperature for approx. 10 minutes.

Switch off diesel engine and allow to cool to approx. 50° C. If the cooling system has cooled to approx. 50° C.

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Caution

Danger of scalding due to degreasing or derusting agent spraying out! ! Only open sealing cap on the expansion tank when the diesel engine has cooled - the coolant temperature display on the segment field should be in the lower third of the segment field.

• • •

Drain decalcifying or degreasing agent.

•

Drain scavenging water, refill cooling system with fresh water and repeat scavenging procedure 3 to 5 times.

•

Dismantle coolant thermostats, manoeuvre into standard position and install with new thermostat housing sealing.

•

Carry out maintenance task “fill coolant ”.

Fill cooling system with fresh water.

Allow diesel engine to run for approx. 5 minutes for scavenging purposes.

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Maintenance

Operating manual

Maintenance tasks

5.3.10 Lifting gear.

Transport Ensure that: – A suitable lifting gear, – and a transport device or special tool nos. 21 and 22 are on-hand as required.

Lifting gear

5.3.11

•

If not already available, mount transport hooks or special tool nos. 21 and 22.

•

Use correct lifting gear only for diesel engine transport.

Suspend diesel engine from the transport hooks provided.

Storage Storage for up to 6 months

Storage between 6 and 24 months.

When putting into storage for between 6 and 24 months, a complete preservation must be acrried out, consult LIEBHERR Service or a LIEBHERR authorised dealer.

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The Liebher diesel is preserved from the date it becomes ready for dispatch, with standard storage in a dry, well ventilated site, the effective preservation period is 6 months.

Should the diesel engine be additionally covered with a tarpaulin sheet, it can also be stored outdoors for up to a month.

The cover must be water-tight and lay loosely over the diesel engine in order that the air can circulate around the diesel engine, preventing the formation of condensation.

Should the specified measures be deviated from, whereby the preserved diesel engine is submitted to unfavourable conditions (extended periods of outdoor storage, or storage in damp, poorly venilated sites etc.), a shorter effective preservation period must be considered.

Operating manual

Maintenance Maintenance tasks

Removing the preservation after 6 months in storage.

•

Remove all mounted connections.

If required (e.g. when checking for leaks), the exterior preservation must be removed thoroughly using degreasing solvent, white spirit or petroleum.

Should high-pressure equipment be applied, white spirit is recommended as a solvent.

Intensive spraying of rubber-plastic components, as well as water temperatures exceeding 80 are to be avoided as irreversible damage could be resulted.

•

5.3.12

Following mounting and connection of the diesel engine.

Fill permissible fuel to the maximum level, see “Fuel and lubricants ”..

Comfirmation of maintenance tasks carried out.

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Maintenance details

Diesel engine type:

.............................................................................

Diesel engine no.:

..............................................................................

Start-up on:

.............................................................................

Customer:

.............................................................................

Site:

.............................................................................

Street:

.............................................................................

Liebherr - authorised office:

.............................................................................

Site:

.............................................................................

Street:

.............................................................................

Telephone/Fax:

.............................................................................

Note: Operation and maintenance is decisive as to whether the diesel engine is constantly ready for operation and can be operated for extended periods.

We strongly recommend that the prescribed maintenance tasks be carried out carefully and punctually. Only then can the warranty claim be honoured. Lead seals on the injection pump and speed regulator may essentially mot be triggered!

Correct performing of maintenance tasks must be entered and confirmed in the following maintenance chart.

The maintenance tasks for the daily and 50 operating hours maintenance intervals must be carried out by the service personnel of the customer.

The first oil-change and oil filterchange, as well as all further maintenance tasks, must be carried out by a LIEBHERR trained contract mechanic.

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Maintenance

Operating manual

Maintenance tasks

Every 500 operating hours / at least once a year.

–

Under more difficult operating conditions.

• Repetitive cold starts, • Fuel sulphur content above 0.5 %, • Operating temperature below -10 °C, • Oil quality,

f the prescribed oil-change interval has to be halved, see “Fuel and lubricants ”

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Date

Mechanic

Signature

Comment

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Hours 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000 8500 9000 9500 10000 10500 11000 11500 12000 12500 13000 13500 14000 14500 15000 15500 16000 16500 17000 17500 18000 18500 19000 19500 20000

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Operating manual

Maintenance Maintenance tasks

Additionally every 1000 / 2000 / 3000 operating hours Hours 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000

Date

Mechanic

Signature

Comment

Additionally every 2 years Date

Mechanic

Signature

Comment

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Hours 2 years 4 years 6 years 8 years 10 years 12 years 14 years 16 years 18 years 20 years

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Maintenance

Operating manual

Lubricants and fuels

5.4 Lubricants and fuels

5.4.1

Handling lubricants and fuels Conscientous adherence of the guidelines for handling fuel and lubricants increases the reliability and life-expectancy of the diesel engine.

It is especially important that the prescribed quality of lubricants is adhered to.

The diverse details concerning the prescribed intervals can be located in the chapters “Maintenance and inspection chart ”.

The diverse details for carrying out lubrication, level inspection and changing of the fuel can be located in the chapter “Maintenance ” under “Maintenance tasks .. . . ” . .

Handling of the fuel and lubricants should be carried out as follows, and note also the environmental-protection guidelines.

Envirionmentally protective measures.

• • •

Environmentally protective measures must always be met.

Note the guidelines valid for the respective country.

Before draining fluids, ensure that correct disposal has already been organised.

Disposing of waste materials.

These materials include for example: – Oils,lubricants, coolant, cooling agents from cooling systems etc.

– Fuels – Filter, oil filter cartridges, etc.

• Note guidelines for environmental protection when disposing of waste materials.

•

Collect all materials separately in suitable containers, store and dispose of at the official disposal sites in an environmentally-friendly manner.

•

Note the guidelines valid for the respective country.

Disposal

Ensure when refilling that the quantity of anticorrosive and antifreeze does not fall below 50 Vol.-% due to loss of coolant.

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Handling coolants.

Operating manual

Maintenance Lubricants and fuels

Caution

Risk of damage to the diesel engine!

Should the quantity of anticorrosive or antifreeze be decreased, this could in turn lead to damage to the diesel engine! ! Do not use more than 60% anticorrosive or antifreeze.

5.4.2

•

Included in the maintenance tasks is the checking, and if required correction, of the mix ratio for anticorrosive or antifreeze, as well as the DCA 4 – concentration.

• •

For the inspection, use test kit CC 2602 M from Fleetguard.

To fill in a new coolant:check cooling system for cleanliness and scavenge if necessary.

Lubricant and fuel specifications Diesel fuel.

Specification.

The diesel fuels must correspond with the minimal requirements of the fuel specifications listed as follows.

Permissible fuel specifications: – DIN EN 590 – ASTM D 975-89a 1D and 2D Further fuel specifications only after consultation with Diesel engine development, LIEBHERR Machines Bulle S.A. The sulphur content may not exceed 0.5 weight -%. A higher sulphur content affects the oil-change intervals and life-expectancy of the diesel engine.

The problematic nature of the lubricity of the diesel fuel becomes evident with the reduction of sulphur content. It has been proven that diesel fuels can cause up to a max. 0.05 weight -% sulphur deteriation in the injection system for the limits valid today in Europe ( with the distributor injection valves in particular).

"Brand-name fuels" (in Germany DIN EN 590) contain these lubricant additives in their additive package. Lubricity of the fuel must correspond with HFRR(60°) Test <400 µm.

For fuels with specifications in accordance with ASTM, the fuel lubricity must be absolutely guaranteed in accordance with HFRR(60°) Test <400 µm.

The additive should be added by the supplier as the person responsible for quality of the fuel. Addition of secondary-lubricity-additives by the customer is not recommended.

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Lubricity.

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Maintenance

Operating manual

Lubricants and fuels

Diesel fuel at low temperatures.

With ambient temperatures below approx. 0 °C, the flow capacity, and in turn the paraffin separation, can be insufficient with summer diesel fuel.

The same applies for winter diesel fuels below approx. -15 °C. Fuel with additive is also often offered with an operating temperature of down to -20 °C. In order that faults in operation be avoided, the diesel fuel must be mixed with normal benzine or petroleum when operarating in low temperatures.

Mixing of normal benzine must be considered an emergency aid nd may not exceed 30 vol.-%.

Super benzine may not be used for mixing.

The diesel engine output may anneal with the addition of cold-start aids, in accordance with the mixture added. Thus, mixing should be retained as low as possible, taking the respective ambient temperature into consideration.

For safety reasons, the fuel mix should only be realised in the fuel tank.

When refuelling, te specifically lighter additional fuel should be filled in before the diesel fuel. Then the diesel engine should be started and operated for as long as it takes for the entire fuel system to have mixed fuel available to it.

Diesel fuels – Mix ratio (Vol.-%) Ambient temperaSummer diesel fuel % tures °C 0 to -10 70 -10 to -15 50 -15 to -20 --20 to -25 -Mix ratio for summer diesel fuels.

Additive % 30 50 * ---

* should an additive of 50 % be required, only petroleum (no normal benzine) may be used.

Ambient temperature °C — 0 to –10 –10 to –15 –15 to –20 –20 to –25

Winter diesel fuel %

Additive %

–15 °C –20 °C –15 °C 100 100 — 100 100 — 70 100 30 50 70 50* Mix ratio for winter diesel fuels.

–20 °C — — — 30

Additives for the diesel fuel (for flow improvement)

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Flow improvers, available from the store, also contribute to improvement of the cold aptitude of the diesel fuel. If they are used, the dosing and application guidelines of the manufacturer should be noted.

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* should an additive of 50 % be required, only petroleum (no normal benzine) may be used.

Operating manual

Maintenance Lubricants and fuels

Coolant for diesel engines.

Anticorrosive and antifreeze.

To improve quality of the cooling water, water filter accessories for LH diesel engines can be implemented.

As a result of these measures, the coolant is additionally filtered in the induction current and freed of dirt or rust particles which can cause leaks to the coolant pumps.

Furthermore, the cooling system, or parts which come into contact with the coolant, such as coolant pumps, cylinder liners, etc. are protected against cavitation, corrosion, incrustations and the formation of foam due to a chemical additive to the filter (DCA 4).

Coolant with DCA 4 (DCA 4 = Diesel Coolant Additives)

The coolant must contain at least 50 Vol.-% anticorrosive / antifreeze the whole year round. This corresponds with a freeze protection down to approx. -37 °C. With loss of coolant, it must be ensured that the 50 vol.-% is not fallen short of.

Caution!

Risk of damage to the diesel engine!

With too high a quantity of anticorrosive / antifreeze, the cooling effect is reduced and this in turn then leads to damage to the diesel engine!

Do not use more than 60% anticorrosive / antifreeze.

Do not use more than 60% anticorrosive / antifreeze and DCA 4 – concentration must be checked and corrected if necessary.

The DCA 4 concentration must be between 0.3–0,8 units per litre.

For testing, it is recommended that the test set CC 2602 M from Fleetguard be used.

The prescribed change interval for coolant is 2 years.

Before new coolant can be filled, check cooling system for cleanliness and scavenge if necessary.

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Mix ratio.

Temperature-dependent selection of the mix ratios of anticorrosive and antifreeze.

A = Quantity of antifreeze in %.

New filling of the cooling system.

When filling or refilling the cooling system following repair work, as well as the DCA 4 – concentration contained in the water filters, DCA 4 in liquid form must be mixed with the anticorrosive / antifreeze.

DCA 4 is available in cannisters (each container approx. 0.47 litres).

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Maintenance

Operating manual

Lubricants and fuels

DCA 4– water filter Content in litres Containers Litres Term ident no.

WF2071 24 — 39 3 1.4 7367045 WF2072 40 — 59 4 1.9 7381493 WF2073 60 — 79 5 2.4 7367052 WF2073 80 — 115 8 3.8 7367052 Required amount of DCA-4 when filling the cooling system.

Cooling system Required amount of DCA 4 – fluid

Fresh water guidelines.

For treatment of the coolant, clean water which is not too hard must be used. Most of the time, although not always, tap water meets the desired requirements.

Sea water, stream water, brine and industrial waste water are not suitable.

Term Value and unit Amount of alkaline earth (water 0.6 to 2.7 mmol/ l (3 to15 ° d) hardness) Ph-value at 20 °C 6.5 to 8.0 Chloride-ion content max. 80 mg/ l Sulphate-ion content max. 80 mg/ L Fresh water quality when using coolant with DCA 4.

Utilisation of DCA 4 without anicorrosive or antifreeze.

In exceptional cases and with ambient temperature constantly above freezing point, e.g. in tropical climates, where there is quite evidently no authorised anticorrosive or antifreeze available, water and DCA 4 may be used as coolant –.

In order that the cooling system also be protected against corrosion: – Roughly double the amount of DCA 4 must be used as opposed the mix ration of anticorrosive / anifreeze and DCA 4.

– The DCA 4 – concentration must be between 0.6 and 1.06 units per litre.

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Included in the maintenance tasks, the DCA 4 – concentration must be checked and corrected if necessary.

The coolant must be changed once a year.

When using water + DCA 4, no cooling water-refining agent (anticorrosive oil) may be used.

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Operating manual

Maintenance Lubricants and fuels

Authorised anticorrosive / antifreeze A

MARKE Agip Antifreeze Plus Agip-Auto Langzeit-Frostschutz Antigel DB 486 Aral Antifreeze Extra Aral Antifreeze T Avia Antifreeze APN

B

BP Antifrost X 2270 A BP Napgel C 2270/1

D

DEA Kühlerfrostschutz DEUTZ Kühlschutzmittel 0101 1490 DOW Kühlmittel D 542 / 1993

F

Frostschutz 600

G

I

Glacelf SX Glyco Shell Glysantin (G 48-00) Igol Antigel Type DB

M

Motul Anti-Freeze

O

ÖMV - Kühlerfrostschutzmittel OZO Frostschutz S Total Multiprotect

LMB /01 /003801 //6.2/en /Version :

T

HERSTELLER Agip Petroli S.p.A Rom Italien Agip Schmiertechnik GmbH, Würzburg Sotragal SA, St. Priest / Frankreich Aral AG, Bochum Aral AG, Bochum Deutsche Avia-Mineralöl GmbH, München Deutsche BP AG, Hamburg BP Chemicals Ltd., London/England DEA Mineral AG, Hamburg DEUTZ Service International GmbH, Köln BOSS Chemie AG, Wittenbach/Schweiz Mobil Schmierstoffe GmbH, Hamburg Elf Lubrifiants Paris/Frankreich Shell Chemie GMBH, Eschborn BASF AG, Ludwigshafen Igol France, Paris/Frankreich Motul SA, Aubervilliers Cedex/Frankreich ÖMV AG, Wien/Österreich Total Deutschland GmbH, Düsseldorf Total Deutschland GmbH, Düsseldorf

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Maintenance

Operating manual

Lubricants and fuels

Lube oils for the diesel engine.

Lube oil quality.

Only high-alloy lube oils are used today for modern diesel engines.

They comprise of base oils, with which additives are mixed..

The lube oil guidelines for LIEBHERR diesel engines are based on the following specifications and guidelines:

Term Specification ACEA (CCMC) — Klassifikation (Association des Constructeuers E2, E3, E4, E5, (D4, D5) Européens de l'Automobile) API — Klassifikation (American PeCG–4, CF–4, CH–4 troleum Institute) Lube oil viscosity.

Selection of lube oil viscosity is resulted in accordance with SAE classification (Society of Automotive Engineers).

The ambient temperature is decisive for correct selection of the SAE class.

Selection of the SAE classification gives absolutely no indication of the quality of a lube oil.

Too high a viscosity can cause difficulties when starting and too low a viscosity can impair lubrication effiiency.

Temperature ranges specified in the graphic are guidelines which can be exceeded or fallen short of.

Temperature-dependent selection of the SAE class.

Change intervals.

– First oil and filter change with utilisation of initial filing oil: see chapter “Maintenance and inspection chart ” – Oil change depending on climatic region, sulphur content in the fuel and oil quality in accordance with the following table.

Should the specified operating hours (Bh) for one year not be reached, diesel engine oils and filters must be changed at least once a year.

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Lube oil change intervals.

Operating manual

Maintenance Lubricants and fuels

Difficulty factors.

Varying difficulty factors or more difficult operating conditions change the maintenance intervals.

Difficulty factors or more difficult operating conditions may include: – Repetitive cold starts.

– Sulphur content in fuel above 0.5% – Operating temperature below -10 °C Should difficulty factors or more difficult operating conditions arise, the prescribed oil-change intervals in the “Maintenance and inspection chart ” must be halved in accordance with the following table.

Difficulty factor

Oil quality E2 D4 CG–4 CF4 CH–4

Operating conditions Climate normal up to –10 °C

Sulphur content in fuel up to 0.5%

E3 E4 E5 D5 Interval

250 Bh

above 0.5% 125 Bh below –10 °C up to 0.5% 125 Bh above 0.5% Oil change intervals in operating hours (Bh)

500 Bh 250 Bh 250 Bh 125 Bh

Sealing agents, safety agents and greases for diesel engines.

This arrangement includes sealing agents, safety agents and greases necessary for maintenance tasks to the diesel engine.

Utilisation is described in the respective assembly or maintenance procedures in the “Service Manual ” for diesel engines.

Sealing agents and safety agents.

LMB /01 /003801 //6.2/en /Version :

Greases

Omnivisc 1050 or Hylomar SQ 32/M or Reinzoplast Loctite 222 or Omnifit 50 M Loctite 243 Loctite 262 or Omnifit 100 M Loctite 270 or Omnifit 200 M Loctite 577 Loctite 648 or Omnifit 230 M Molykote Longterm 2 Plus Barrierta L55/3 Staburags NBU 12

D924 T-E/TI-E - D926 T-E/TI-E -/2000010000 LIEBHERR

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