Liebherr Diesel engine D936 A7-04 D946 A7-04 LWE Operator's manual

Operator's manual Diesel engine D936 A7-04 / D946 A7-04 / LWE From serial number 2019040001

en

Document ID Order number: Issued: Version: Author:

ORIGINAL OPERATOR'S MANUAL 12978724 01.07.2020 02 LMB / KD32

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

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

Diesel engine D936 A7-04 / D946 A7-04 / LWE 2019040001

Only for the United States

WARNING

WARNING

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

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

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

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

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

- Do not modify or tamper with exhaust system.

- Do not idle the engine except as necessary.

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

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

D936 A7-04 / D946 A7-04 / LWE / 2019040001

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

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Operator's manual

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D936 A7-04 / D946 A7-04 / LWE / 2019040001

Change history

Version From serial number 00

01

02

Changes included

Issue

2019 04 0001

Document newly created This operator’s manual is valid for LWE

12/16/2019

2019 04 0001

Exhaust aftertreatment system control and warning lamps chapter revised. (For more information see: Exhaust aftertreatment system control and warning lamps, page 20.)

Exhaust aftertreatment system warning and malfunction strategies chapter revised (For more information see: Exhaust 1/24/2020 aftertreatment system warning and malfunction strategies, page 21.)

Cleaning hydrocarbon (HC) deposits chapter revised. (For more information see: Cleaning hydrocarbon (HC) deposits, page 26.)

2019 04 0001

Exhaust aftertreatment system warning and malfunction strategies chapter revised (For more information see: Exhaust aftertreatment system warning and malfunction strategies, page 21.)

Checking the (optional) fan drive V-ribbed belt tension chapter revised. (For more information see: Checking the (optional) 7/1/2020 fan drive V-ribbed belt tension, page 73.)

Checking the (optional) air conditioning compressor V-ribbed belt tension chapter revised. (For more information see: Checking the (optional) air conditioning compressor V-ribbed belt tension, page 75.)

Change history

D936 A7-04 / D946 A7-04 / LWE / 2019040001

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Operator's manual

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D936 A7-04 / D946 A7-04 / LWE / 2019040001

Preface

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

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

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

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

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

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

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

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

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

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

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

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

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

D936 A7-04 / D946 A7-04 / LWE / 2019040001

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Preface

Operator's manual

About the document

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

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

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

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

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Operator's manual

Preface Graphic symbols in these instructions

Graphic symbols in these instructions Symbol

Meaning Note Identifies useful information and tips.

Prerequisite Identifies conditions for the following action steps.

Call to action Identifies action steps.

Result Identifies results of one or more action steps.

–

Itemization Identifies individual points of a list.

Graphic symbols

D936 A7-04 / D946 A7-04 / LWE / 2019040001

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Preface

Operator's manual

Changes, conditions, copyright

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

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

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D936 A7-04 / D946 A7-04 / LWE / 2019040001

Contents

1

Product description

17

1.1

Technical description

17

1.1.1

Design

17

1.1.2

Exhaust aftertreatment system SCRonly

19

1.1.3

Engine type itemization

26

1.1.4

Company nameplate

27

1.1.5

Cylinder designation, direction of rotation

29

1.1.6

Engine control unit type plate (ECU2)

30

1.1.7

Exhaust aftertreatment system type plate

31

1.2

2

Technical data

33

1.2.1

Diesel engine

33

1.2.2

Valve clearance

33

1.2.3

Valve clearance, auxiliary braking system (ABS)

33

1.2.4

Coolant thermostat

34

Safety

35

2.1

Labeling of warnings

35

2.1.1

35

Additional labels

2.2

Target group

36

2.3

Intended use

36

2.4

Foreseeable misuse

36

2.5

General safety instructions

37

2.6

Preventing personal injuries

39

2.6.1

Bruises

39

2.6.2

Burns and scalds

39

2.6.3

Fires and explosions

39

2.6.4

Poisoning

39

2.6.5

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

40

2.6.6

Electrical energy

40

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Contents

Operator's manual

2.6.7

Personal protective equipment

40

2.8

Operating areas and maintenance areas

41

2.8.1

Safety instructions

41

2.8.2

Operating areas

42

2.8.3

Maintenance areas

42

2.8.4

Securing and releasing the diesel engine against accidental start-up

43

2.8.5

Emergency stop

44

5

Signage

44

2.10 Preventing property damage

45

Transport and storage

47

3.1

Dimensions and weights

47

3.2

Lifting the engine

48

3.3

Transport

50

3.3.1

Transport attachment

50

3.3.2

Transport device

51

3.4

4

Storage

53

3.4.1

Storage

53

3.4.2

Storage time

57

Operation

59

4.1

Preliminary work for the initial commissioning of the engine

59

4.2

Starting the engine

60

4.3

Turning off the engine

62

Maintenance

63

5.1

Maintenance schedule

63

5.2

Preliminary work

66

5.2.1

Bringing the engine into maintenance position

66

5.2.2

As needed

66

5.3

Diesel engine

72

5.3.1

Checking the V-ribbed belt for damage

72

5.3.2

Checking the V-ribbed belt for tension

72

5.3.3

Checking the belt drive

76

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40

2.7

2.9

3

Danger due to noise

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Operator's manual

Contents

5.4

5.5

5.6

5.7

5.8

5.9

5.3.4

Replacing the belt drive

91

5.3.5

Checking the engine mount

106

5.3.6

Checking the intake system for leaks and damage

107

5.3.7

Checking the exhaust system

108

Engine oil system

109

5.4.1

Checking the engine oil system for leaks and damage

109

5.4.2

Checking the engine oil level

112

5.4.3

Changing the engine oil

113

5.4.4

Replacing the oil separator filter insert

119

Cylinder head

123

5.5.1

123

Checking and setting the valve clearance

Cooling system

139

5.6.1

Checking the cooling system and heating system for leaks and damage

139

5.6.2

Checking the coolant level

140

5.6.3

Checking the concentration of the antifreeze agent in the coolant

140

5.6.4

Replacing the coolant

141

Fuel system

145

5.7.1

Checking the fuel system for leaks and damage

145

5.7.2

Replacing the fuel prefilter

146

5.7.3

Reducing the pressure in the fuel system

146

5.7.4

Replacing the fuel fine filter

146

5.7.5

Ventilating the fuel system

149

Air filter

151

5.8.1

Checking the air filter low pressure indicator

151

5.8.2

Cleaning the air filter dust discharge valve

151

5.8.3

Replacing the dry air filter main element

151

5.8.4

Replacing the dry air filter safety element

151

Electrical system

152

5.9.1

Checking the batteries

152

5.9.2

Checking the cable connections

152

5.9.3

Checking the engine control unit bearings for damage

152

5.9.4

Checking sensors, actuators, cable holders and plugs

153

5.9.5

Checking the heating flange

154

5.9.6

Replacing the heating flange

157

5.10 Exhaust aftertreatment system

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Contents

Operator's manual

6

7

159

5.10.2 SCROnly

159

5.10.3 Check components

160

5.10.4 SCRonly

160

5.11 Lubricants and operating fluids

162

5.11.1 Fill quantities

162

5.11.2 Engine oils for diesel engines with emission limit stage Tier 4 Final

162

5.11.3 Coolant

163

5.11.4 Fuel for diesel engines with emission limit stage Tier 4 Final

164

Malfunctions

165

6.1

165

Faults - Cause - Remedy

Tools and devices

171

7.1

171

7.2

8

5.10.1 Checking the exhaust aftertreatment system for leaks and damage

Tools 7.1.1

Special tool

171

7.1.2

Operating material

172

7.1.3

Diagnostic tools

172

Devices

173

7.2.1

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

173

7.2.2

Lifting traverse with two-point-raising

175

7.2.3

Engine assembly stand

176

7.2.4

Transport device

177

Appendix

179

8.1

Tightening torques

179

8.1.1

For hex bolts / cylinder screws / external hex bolts

179

8.1.2

For locking screws and banjo bolts

181

8.1.3

Standard torques for metric flange connections

182

8.1.4

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

183

8.1.5

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

184

8.1.6

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

184

8.1.7

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

185

8.1.8

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

186

8.2

Supplemental Information USA

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Contents

8.2.1

Emission warranty

190

8.2.2

Warranted parts

190

8.2.3

RESPONSIBILITIES & LIMITATIONS

190

8.2.4

Exclusions

191

8.2.5

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT (CALIFORNIA ONLY)

193

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Contents

Operator's manual

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D936 A7-04 / D946 A7-04 / LWE / 2019040001

1 Product description

1.1 Technical description 1.1.1 Design

Fig. 1: Unit carrier side 1 2 3 4 5 6 7

Viscous damper Air conditioning compressor (optional) Deflection pulley V-ribbed belt Alternator Oil filter Water cooler supply

D936 A7-04 / D946 A7-04 / LWE / 2019040001

8 9 10 11 12 13 14

Compensation tank supply Exhaust manifold Suspension device Exhaust gas turbocharger Exhaust gas stub Oil cooler Water cooler return

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Product description

Operator's manual

Technical description

Fig. 2: Flywheel side 1 2 3 4 5 6 7

Flywheel Oil dipstick Control unit Oil separator Crankcase ventilation Air intake pipe Cylinder head cover

8 9 10 11 12 13

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Oil filter Heating flange Fuel fine filter Air compressor Fuel high pressure pump Oil pan

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Operator's manual

Product description Technical description

1.1.2 Exhaust aftertreatment system SCRonly

Fig. 3: Exhaust system 1 2 3 4

Sensor pipe Outlet module Reduction agent injector Mixing pipe

D936 A7-04 / D946 A7-04 / LWE / 2019040001

5 6 7 8

SCR inlet module NOx sensor Temperature sensor Reduction agent pump

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Product description

Operator's manual

Technical description

17 NOx

1

22

3

21

T

16

15

24

26 23 10 9

PAir

NOx NH3

25

6

18 19

11 27 8

4

13

20 PT DEF

12 28

2 5

7

Fig. 4: Exhaust aftertreatment system 1 2

Coolant supply Coolant return

11 12

3 4 5

Air supply Ventilation Reduction agent suction module 1 Reducing agent line heater 1

13 14 15

Coolant control valve 1 Coolant control valve 2 Reducing agent dosing system 1 Air pressure sensor

6 7 8 9 10

Air control valve Reducing agent temperature pressure sensor Reduction agent pump Reducing agent line heater 2 Reduction agent injector

21 22

Exhaust inlet (device side) Engine exhaust pipe

23 24 25

Exhaust system Mixing pipe Air line

26

Coolant line

17 18 19

Temperature sensor for exhaust system 1 inlet NOx sensor 1 inlet NOx sensor 1 outlet SCR NH3 sensor 1

27 28

Reducing agent line Control unit SCR NH3 sensor

20

Exhaust outlet

16

Exhaust aftertreatment system control and warning lamps The various states of the exhaust aftertreatment system are shown to the operator through the illumination of the corresponding control lamps in the display. The pictograms are examples and can differ in the various devices and depending on the exhaust aftertreatment system installed.

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Operator's manual

Product description Technical description

Lamp

Designation

Meaning

EESF lamp (Engine emission system failure)

Exhaust aftertreatment system malfunction or reduction agent tank fill level not OK

MIL lamp (Malfunction Indicator Lamp)

Reduction agent lamp

Filter module lamp (filter module)

Illuminates depending on the soot load

AWL lamp (Amber Warning Lamp)

Action required during the next maintenance

RSL lamp (Red Stop Lamp)

Engine stop required

Manual interruption or termination of the regeneration

HEST lamp (High Exhaust System Temperature)

High exhaust temperatures

Torque limitation to relieve the exhaust aftertreatment system.

Tab. 1: Exhaust aftertreatment system control and warning lamps

Exhaust aftertreatment system warning and malfunction strategies The exhaust aftertreatment with SCR (Selective Catalytic Reduction) describes a technique for the conversion or reduction of nitrogen oxides (NOx) in the exhaust into nitrogen (N2) and water (H2O) by adding a reducing agent (urea solution).

The exhaust aftertreatment system is monitored by a diagnostics system. If the diagnostics system detects an error, a warning or malfunction strategy is activated.

Operating the device with a malfunction over several operating hours will have the result that the power limitation cannot be deactivated, even through an ignition change. A repair of the device is absolutely necessary. If an additional error detection takes place after resolving the problem, the limitations will be run through in a shorter period of time.

D936 A7-04 / D946 A7-04 / LWE / 2019040001

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Product description

Operator's manual

Technical description

Note The restrictions occur in stages.

Display (pictograms are examples)

MIL off

Reducing agent lights up yellow continuously.

Acoustic signal

MIL flashes or lights up yellow continuously

System status

Restrictions

Reduction agent level < 10 % or malfunction of exhaust aftertreatment system.

No restriction

Reduction agent level < 5 % or malfunction of exhaust aftertreatment system

Low power limitation

Remedy

Acoustic signal Reducing agent lights up yellow continuously.

Reduction agent level < 2.5 % or malfunction of exhaust aftertreatment system

MIL flashes or lights up yellow continuously.

Refill reduction agent. In case of malfunction, High power contact Liebherr limitation customer service.

Acoustic signal Reducing agent flashes or lights up red continuously.

Reduction agent level < 0 % or malfunction of exhaust aftertreatment system

MIL flashes or lights up red continuously.

Acoustic signal Reducing agent flashes or lights up red continuously.

Tab. 2: Exhaust aftertreatment system warning and malfunction strategies

Stationary operation (for example, crane operation at construction site) Note The reduction agent tank is deemed empty as of a fill level of <2.5%.

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Operator's manual

Product description Technical description

100% 75%

20% 30 min

10 min < 10%

< 5%

~2.5%

0%

Fig. 30: Warning and malfunction strategy sequence for low reduction agent level 1 2

Reduction agent fill level Available torque

3

Available torque curve

100% 75%

20% 0 min

60 min

70 min

170 min

200 min

Fig. 31: Warning and malfunction strategy sequence when errors occur in the exhaust aftertreatment system 1 2

Time elapsed Available torque

3 4

Occurrence of the error Torque reduction curve

Driving operation (for example, undercarriage drive) Note The speed limitation is only used for applications that are approved for road use.

D936 A7-04 / D946 A7-04 / LWE / 2019040001

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Product description

Operator's manual

Technical description

45 mph 73 km/h

5 mph 7 km/h

30 min

10 min < 10%

< 5%

~2.5%

0%

Fig. 32: Warning and malfunction strategy sequence for low reduction agent level 1 2

Reduction agent level Available speed

3

Speed curve

no limit 45 mph 73 km/h

5 mph 7 km/h

0 min

60 min

70 min

170 min

200 min

Fig. 33: Warning and malfunction strategy sequence when errors occur in the exhaust aftertreatment system 1 2

Time elapsed Speed

3 4

Occurrence of the error Speed curve

Repeated occurrence of an error A repeated occurrence of a malfunction is defined as two or more error messages with activated warning system, which occur within a period of 40 engine operating hours. The repeated occurrence of a malfunction applies for the recurrence of all error codes that trigger the warning system, with the exception of errors relating to the reduction agent level, and is not limited to the repetition of the same error code. The repeated occurrence of a malfunction leads to the final warning level being reached within 30 minutes.

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Operator's manual

Product description Technical description

100 80 60 40 20 0

0

20

40

60

80

100

120

140

160

180

200

220

240

Fig. 34: Time reduction of the warning and malfunction strategy sequence for repeated error detection 1

Time elapsed

3

2

Speed

4

Torque reduction curve for first error detection Torque reduction curve for repeated error detection

Use / handling of reduction agent NOTICE Escaping reducing agent!

Damage to painted surfaces or aluminum surfaces.

Rinse affected surfaces with water immediately.

NOTICE Adding special additives and diluting the reducing agent (for example with tap water)!

Legally prescribed emission limits are not observed.

Destruction of the exhaust aftertreatment system!

Keep the reducing agent absolutely pure.

Make sure that no dirt gets into the reducing agent.

Do not fill any operating fluids in the reducing agent tank.

Do not fill any reducing agent in the diesel fuel tank.

NOTICE Diesel fuel filled in the reducing agent tank or vice versa!

Destruction of the diesel engine or the exhaust aftertreatment system.

Keep the reducing agent absolutely pure.

Do not reuse reducing agent that has been drained.

NOTICE Operation without reducing agent!

Legally prescribed emission limits are not observed and power is severely limited.

Operator is liable to prosecution.

Operate the system with reducing agent.

Refill the reducing agent on time.

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Product description

Operator's manual

Technical description

The reducing agent consumption is based on the use of the vehicle. Refilling is not dependent on maintenance. The reducing agent tank fill level is shown via a tank display in the device cabin. For procedure or information on refilling, see documentation from the device manufacturer.

Cleaning hydrocarbon (HC) deposits During operation of the engine in the low load and speed range, HC particles may accumulate and deposit in the exhaust aftertreatment system. The operating range is therefore monitored and the engine idling speed is increased, if necessary.

Lamp

Torque limitation

Display

-

Torque limitation to 50% Note to the operator through the device display.

Tab. 3: Cleaning hydrocarbon deposits

1.1.3 Engine type itemization Engine type designation D 93 6 A7 -04 Description D

Engine type: D = diesel engine Family (l/cylinder): 93

93: 1.59 l/cylinder 94: 2 l/cylinder 6

Number of cylinders A7

Injection system: A7 = Common Rail System Emission standard: Tier 4 final -04 Exhaust aftertreatment system: SCROnly = Selective Catalytic Reduction

Tab. 4: Engine type itemization

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Operator's manual

Product description Technical description

1.1.4 Company nameplate

Fig. 35: Company nameplate 1 2 3 4 5 6 7 8 9 10

Manufacturer Data matrix code US type approval information Engine power at rated speed Identification number Engine variant (Liebherr internal type) Engine type Capacity Engine serial number Date of manufacture

D936 A7-04 / D946 A7-04 / LWE / 2019040001

11 12 13 14 15 16 17 18 19

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

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Product description

Operator's manual

Technical description

Attachment point

Fig. 36: Company nameplate on the crankcase and on the air intake pipe 1

Company nameplate on the crankcase

2

Company nameplate on the air intake pipe

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

2019 04 0001 Engine serial number 2019

Year of manufacture 04

Type series: 04 = D936 / D946 0001 Sequential production number

Tab. 5: Engine serial number

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Operator's manual

Product description Technical description

1.1.5 Cylinder designation, direction of rotation Firing order, cylinder designation and direction of rotation

Fig. 37: Cylinder designation, engine serial number (example) and firing order 1 2

Engine serial number Firing order

3

Cylinder designation

Direction of rotation

1

2

3

4

5

6

Fig. 38: Cylinder designation and direction of rotation 1

Flywheel side

2

Unit carrier side

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

Viewed from the flywheel 1, the crankshaft turns counterclockwise.

D936 A7-04 / D946 A7-04 / LWE / 2019040001

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Product description

Operator's manual

Technical description

1.1.6 Engine control unit type plate (ECU2)

Fig. 39: Engine control unit type plate ECU2 (example) 1 2 3

Supplier number Control unit serial number Creation date

4 5 6

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

Attachment point

Fig. 40: Type plate on engine control unit 1

Type plate on engine control unit

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Operator's manual

Product description Technical description

1.1.7 Exhaust aftertreatment system type plate Type plate

Ý«­¬±³»® ×Ü

ïïíèîëêè

ÍÛÎ×ßÔ Ò±ò

ÔÎßðëêëçî

ÍËÐÐÔ×ÛÎ ÐßÎÌ Ò±ò ú ×ÍÍËÛ ÔÛÊÛÔ

ÉÍÈÈïêê

ÓßÒËÚßÝÌËÎÛ ÜßÌÛ

ÜÜ ñ ÓÓ ñ ÇÇ

Fig. 41: Sample type plate 1 2 3

DMC code Identification number Serial number

4 5

Supplier part number Date of manufacture

Fig. 42: Sample type plate for spacer 1

Identification number

Mixing pipe and sensor pipe

Fig. 43: Type plate on mixing pipe and sensor pipe 1

Type plate for individual components

D936 A7-04 / D946 A7-04 / LWE / 2019040001

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Product description

Operator's manual

Technical description

Exhaust aftertreatment system SCRonly

Fig. 44: Type plate on inlet module and outlet module 1

Type plate for individual components

2

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32

Type plate for complete system

D936 A7-04 / D946 A7-04 / LWE / 2019040001

Operator's manual

Product description Technical data

1.2 Technical data 1.2.1 Diesel engine Description

Unit Value

Construction

In-line diesel engine

Number of cylinders

6

Firing order

1–5–3–6–2–4

Hole (D936)

mm 122

Hole (D946)

mm 130

Stroke

mm 150

Displacement (D936)

l 10.5

Displacement (D946)

l 11.95

Compression ratio (D936)

17.4:1

Compression ratio (D946)

17.5:1

Direction of rotation of the diesel engine

Viewed from the flywheel: counterclockwise

Power group

LG 0 to LG 2

Rated power

see company nameplate

Rated speed

see company nameplate

Emission limits

Tier 4 final

1.2.2 Valve clearance Description

Unit Value

Valve clearance, inlet, cold

mm 0.3

Valve clearance, outlet, cold

mm 0.4

1.2.3 Valve clearance, auxiliary braking system (ABS) Description

Unit Value

Valve clearance, inlet, cold

mm 0.3

Valve clearance, outlet, cold

mm 0.6

Valve clearance, counterholder, cold

mm 0.4

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Product description

Operator's manual

Technical data

1.2.4 Coolant thermostat Description

Unit Value

Start of opening

°C 82

Completely opened

°C 92

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2 Safety

2.1 Labeling of warnings This is the warning sign. It warns of a potential risk of injury. Follow all measures that are indicated with this warning sign in order to prevent injuries or death.

Tab. 6 The warning sign always appears in connection with the signal words.

DANGER WARNING CAUTION DANGER

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

WARNING

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

CAUTION

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

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

Tab. 7

2.1.1 Additional labels Note Identifies useful information and tips.

Tab. 8

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Safety

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Foreseeable misuse

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

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

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

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

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

– Only use the diesel engine for its intended purpose.

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

• Servicing the diesel engine.

• Maintaining the diesel engine.

Please refer to the “Target audience” chapter for additional information.

– – – – –

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

Pay attention to the safety and operating instructions.

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

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

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

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

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

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

Liebherr assumes no liability for: – Failure to observe these instructions – Incorrect use

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Operator's manual

Safety General safety instructions

– The employment of personnel who do not satisfy the target audience requirements.

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

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

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

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

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

2.5 General safety instructions – Fulfill the requirements of the target groups for the work.

– In order to guarantee help in the event of an accident: • A second person is present • Ensure that the emergency situation will be detected and help with take place.

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

– Only allow the following personnel to work on the gas engine under the constant supervision of an experienced person.

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

• Observe the generally recognized safety and occupational health rules.

• Observe the operator's manual.

– Make sure that the personnel wears the prescribed work clothing. (For more information see: 2.7 Personal protective equipment, page 40.)

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

– Keep the workplace clean and orderly.

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Safety

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General safety instructions

– – – – – –

Make preparations for emergencies that could occur.

Have a fire extinguisher and first aid kit ready.

Have emergency telephone numbers ready.

Make sure that the workplace has sufficient lighting.

Perform installation work only when the engine is secured.

Ensure that the engine is not started by unauthorized individuals.

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Operator's manual

Safety Preventing personal injuries

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

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

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

– Observe the regulations on the lifting points.

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

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

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

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

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

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

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

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

– Avoid contact with parts carrying coolant.

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

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

2.6.3 Fires and explosions – – – –

Do not smoke in the immediate vicinity of the engine.

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

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

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

– Remove rags that are soaked with flammable liquids.

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

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

– Never ingest operating fluids.

– Do not use beverage bottles to store operating fluids.

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

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

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

– Protect hands, face and body against escaping liquids when searching for leaks on lines and hoses that are under pressure. (For more information see: 2.7 Personal protective equipment, page 40.)

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Safety

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Personal protective equipment

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

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

– Check the pressure reduction with the diagnostics software.

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

– Do not open any pressurized fuel lines or hoses.

– Do not disconnect any pressurized fuel lines or hoses.

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

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

– Do not touch any live parts.

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

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

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

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

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

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

2.7 Personal protective equipment Danger due to electrical energy – Wear protective equipment for direct access to engines.

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

• Protective function is guaranteed.

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

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Operator's manual

Safety Operating areas and maintenance areas

Safety helmet – Protection against • Falling or flying object • Bumping your head Safety shoes – Foot protection against • Falling objects • Pinching of the foot in heavy parts • Against slipping Safety gloves – Protection against hot elements and chemicals Wear safety gloves when working with hot parts, for example, • shrinking the gear ring onto the flywheel.

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

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

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

Hearing protection – Protection against noise

Gas detector – Protection against escaping gases

2.8 Operating areas and maintenance areas 2.8.1 Safety instructions Trapping points and mechanical parts flying around when the engine is ready for operation or in operation Serious injuries and risk of death: – Keep away from the operational engine.

– Wear personal protective equipment.

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

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

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

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Safety

Operator's manual

Operating areas and maintenance areas

– Wear personal protective equipment.

– Let the engine cool down sufficiently.

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

– Wear personal protective equipment.

2.8.2 Operating areas A

D

B

B

B

B

C

E

a

b

Fig. 57: Safety zones for the engine that is ready for operation or in operation a

Horizontal plan (view from above)

b

Vertical plan (view from flywheel side)

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

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

WARNING Hot components on the engine!

Serious burns possible.

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

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Operator's manual

Safety Operating areas and maintenance areas

A

D

B

B

B

B

C

E

a

b

Fig. 58: Safety zones for maintenance and servicing a

Horizontal plan (view from above)

b

Vertical plan (view from flywheel side)

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

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

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

– Label cut-off point.

– Disconnect electrical power supply and secure against reactivation.

– Label cut-off point.

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

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

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

– The tags for the fuel supply are removed.

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Safety

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Signage

– Fuel supply is connected.

– Remove the label from the electrical power supply.

– Establish the electrical power supply.

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

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

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

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

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

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

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

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

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

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

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

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

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

Secure the Diesel engine against any unexpected start-up.

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

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

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Operator's manual

Safety Preventing property damage

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

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

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

2.10 Preventing property damage – Replace sealing material, for example, o-rings and seals.

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

– Replace removed, not reusable parts.

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

– Replace self-locking screwed assemblies.

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

– Use lint-free cleaning cloths.

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

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

– Remove covers or adhesives after cleaning.

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

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

– Use suitable test leads for measurements on plug connections.

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

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

– Disconnect the negative pole first and connect it last.

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

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Safety

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Preventing property damage

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3 Transport and storage

3.1 Dimensions and weights

2

1

3

Fig. 64: Dimensions 1 2

Width Height

3

Length

Description

Unit Value

Width

mm 834

Height

mm 1188

Length

mm 1666

Engine weight without operating fluids

kg 1210

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

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Transport and storage

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Lifting the engine

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

Will lead to death or serious injuries due to crushing.

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

Observe maximum weight for lifting points.

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

Use a Liebherr lifting traverse. ( external link to 2001265 [heading], 1) (For more information see: 7.2.1 Lifting traverse with three-point-raising (basic version), page 173.)

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

Observe national and international guidelines for lifting heavy loads.

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

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

NOTICE Improper transport!

Leads to damage to the engine components Make sure that components such as ignition strips and ignition coils (if present) are not damaged by inclined chains when lifting the engine.

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Operator's manual

Transport and storage Lifting the engine

max.10°

max.10°

4 1

4 5

3

4

5

3

3

5

1

1 1

2

B

2

2

D

C

A max.6° max.6° 5

2 E

F

Fig. 65: Lifting the engine A

Transport device detail view

1

B

2

C D

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

E

Lifting traverse lifting point detail view

5

F

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

3 4

Tolerance for maximum deviation of motor axis Crankcase Lifting traverse Engine lifting traverse lifting point (observe maximum total load) Tolerance for maximum horizontal deviation

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

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Transport and storage

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Transport

3.3 Transport 3.3.1 Transport attachment

Fig. 66: Transport attachment

DANGER Instability during transport!

Leads to death or serious injuries.

Only use the original transport device.

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

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

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

Observe the center of gravity.

Bolt the engine securely to the transport device.

DANGER The engine can tip during loading or unloading!

Leads to death or serious injuries.

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

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

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

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

Observe information on the center of gravity.

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Transport and storage Transport

3.3.2 Transport device Wood transport device DANGER Instability during transport!

Leads to death or serious injuries.

Only use the original transport device.

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

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

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

Observe the center of gravity.

Bolt the engine securely to the transport device.

Fig. 67: Wood transport device Only transport the engine using the transport device.

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Transport and storage

Operator's manual

Transport

Steel transport device DANGER Instability during transport!

Leads to death or serious injuries.

Only use the original transport device.

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

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

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

Observe the center of gravity.

Bolt the engine securely to the transport device.

Fig. 68: Steel transport device Only transport the engine using the transport device.

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Transport and storage Storage

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

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

Use the “first in first out” logistics method.

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

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

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

Engine clean and dry Temperature of the engine identical to the ambient temperature (formation of condensation) WARNING Corrosion protection wax is highly flammable!

Burns.

Refrain from open flames.

Refrain from smoking.

VCI film cover LxWxH ID no.

2100x1100x2150

10165707

1250x850x1500

10042128

1250x850x2100

11694088

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Storage

VCI film cover LxWxH ID no.

990x540x1300

11067328

2000x1500x2000

11826670

3200x1500x2000

11826671

540x350x540

11067327

350x250x550

11067326

850x650x800

10331822

Tab. 9: VCI film cover VCI bag LxW ID no.

300x200

11170517

345x260

11170521

Tab. 10: VCI bag Loosely apply the VCI corrosion protection film so it is sealed tight.

Air can circulate.

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

Disposal CAUTION Chemical substances!

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

Use protective gloves.

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

Dispose of VCI corrosion protection film.

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

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

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

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

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

Drying time is 3 hours.

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Transport and storage Storage

Name

Description

ID no.

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

Tab. 11: Corrosion protection wax A)

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

WARNING Corrosion protection wax is highly flammable!

Burns.

Refrain from open flames.

Refrain from smoking.

NOTICE Decommissioning at freezing temperatures!

Damage to engine.

Contact customer service.

Remove the engine from the device or system.

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

CAUTION Wax residues on the floor!

Slipping.

Watch out for wax residues on the floor.

Remove wax residues on the floor.

Clean engine.

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

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

Check the engine for damage.

Check the engine for paint damage.

If any damage exists: Repair the damage.

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

Disposal Properly dispose of corrosion protection wax.

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

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Storage

Corrosion protection wax de-preservation See Cleaning chapter.

Cleaning Cleaning with cleaning agents NOTICE Impermissible cleaning agent!

Damage to surfaces and sealing elements.

Only use suitable, mild cleaning agents.

Only use lint-free cleaning cloths.

Remove lubricant and contaminants.

Remove water residues.

Warm up the engine.

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

Damage to the electronics and seals of the engine.

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

Prerequisites: Shafts and flanges are lubricated.

Openings are covered or taped with protecting caps and guards.

Seals and closures are tight.

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

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

NOTICE Steam jet comes in contact with temperature sensors!

Activation of the extinguishing system.

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

NOTICE High pressure cleaner comes in contact with sensitive components!

Damage to the electronics and seals of the engine.

Do not point the high pressure cleaner at sensitive components. (For example, rotary shaft lip seals, electrical connections, electronic components)

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Transport and storage Storage

Blow the engine dry with a compressed air gun.

Remove protective covers completely.

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

Remove water residues.

3.4.2 Storage time Condition

up to 1 month

1 to 6 months

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

under UV-resistant tarpaulin

6 to 24 months

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

Tab. 12: Storage time Observe the storage time.

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Storage

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4 Operation

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

Provide a suitable engine oil for the engine. (For more information see: 5.11.2 Engine oils for diesel engines with emission limit stage Tier 4 Final, page 162.)

Fill the oil. (For more information see: Filling the engine oil, page 118.)

Check oil filter connection.

Provide coolant with the correct coolant composition. (For more information see: 5.6.3 Checking the concentration of the antifreeze agent in the coolant, page 140.)

Fill the coolant, see documentation from the device manufacturer.

Check coolant line connections.. (For more information see: 5.6.1 Checking the cooling system and heating system for leaks and damage, page 139.)

Connect air intake, see documentation from the device manufacturer.

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

Connect fuel supply, see documentation from the device manufacturer.

Provide diesel fuel with the approved fuel specification. (For more information see: 5.11.4 Fuel for diesel engines with emission limit stage Tier 4 Final, page 164.)

Fill the diesel fuel.

Ventilate the fuel system. (For more information see: 5.7.5 Ventilating the fuel system, page 149.) (For more information see: 5.11.4 Fuel for diesel engines with emission limit stage Tier 4 Final, page 164.)

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

Check fuel fine filter connection. (For more information see: Removing the fuel fine filter, page 146.)

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

Upload current software update to engine control unit. (For more information see: 1.1.6 Engine control unit type plate (ECU2), page 30.)

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Starting the engine

4.2 Starting the engine Make sure that the following prerequisites are met: During the initial commissioning: Preliminary work for the initial commissioning of the engine has been performed. (For more information see: 4.1 Preliminary work for the initial commissioning of the engine, page 59.)

Oil level is correct.

Coolant is filled, see documentation from the device manufacturer.

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

Exhaust gas disposal is ensured.

The electrical power supply is ready.

The fuel supply is connected.

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

(For more information see: 5.1 Maintenance schedule, page 63.)

DANGER Unexpected movements!

Death or serious injuries possible.

Never bypass the starter.

Never activate the starter directly.

DANGER Unexpected movement of the system!

Death or serious injuries possible.

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

Bring all protective devices into the protective position.

Close the enclosure.

Secure external parts against unexpected movement.

NOTICE Insufficient lubrication!

Damage to engine.

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

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

Determine cause and rectify. (For more information see: 6.1 Faults - Cause - Remedy, page 165.)

NOTICE Continuous operation!

Damage to starter.

Let the starter run a maximum of 30 seconds.

Start the engine.

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

Start the engine.

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Operation Starting the engine

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

Start the engine.

If the engine does not start with the third attempt: Determine cause and rectify. (For more information see: 6.1 Faults - Cause - Remedy, page 165.)

Check oil pressure gauge immediately after starting the engine.

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

Determine cause and rectify. (For more information see: 6.1 Faults - Cause - Remedy, page 165.)

NOTICE Impermissible loading of the engine in cold condition!

Damage to engine.

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

NOTICE Continuous operation at low speed!

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

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

Coolant temperature >60 °C

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Turning off the engine

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

Damage to engine.

Turn off the engine at idling speed.

Reduce engine speed to idling speed.

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

Turn off the engine.

Turn off ignition.

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

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

Damage to reduction agent lines and valves.

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

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

Turn off engine with emergency stop switch.

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5 Maintenance

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

Power groups Devices LG 0 - LG 2

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

Tab. 13: Power groups

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

Tasks to be performed intervals (the earlier date is decisive)

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

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

1000 h

Diesel engine Check V-ribbed belt.

72

1000 h

Check belt drive.

76

1000 h

Check the engine mount.

106

500 h

1000 h

Check the intake system.

107

500 h

1000 h 5000 h / every five years

Check exhaust system.

108

Replace belt drive.

91

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

109

Check engine oil level.

112

Replace engine oil and oil filter.

113

Replace oil separator filter insert.

119

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

Cylinder head Check and set valve clearance.

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

139

Check coolant level.

140

Check the concentration of the antifreeze agent.

140

Replace coolant.

141

10 h

Fuel system Check fuel system for leaks and damage.

145

1000 h

Replace the fuel prefilter.

146

1000 h

146

10 h

Replace fuel fine filter.

Air filter Check the air filter low pressure indicator.

50 h

Clean the air filter dust discharge valve.

151

Replace the dry air filter main element.

151 151

151

1000 h

Replace the dry air filter safety element.

Electrical system Check engine control unit bearings for damage.

500 h

1000 h

Check the batteries.

152

500 h

1000 h

Check cable connections.

152

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Maintenance Maintenance schedule

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

Tasks to be performed intervals (the earlier date is decisive)

500 h

1000 h

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

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

153

Check heating flange, if present.

154 157

10 h

Replace heating flange, if present.

Exhaust aftertreatment system Check exhaust aftertreatment system for leaks and damage.

1000 h

Check components

160

10000 h

50 h

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

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159

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Preliminary work

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

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

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

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

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

Removing the fan

Fig. 69: Fan drive (rigid) 1 2

Hex nut Fan

3

Threaded bolt

Unscrew hex nut 1.

Remove fan 2.

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Maintenance Preliminary work

Removing the fan

Fig. 70: Fan drive (electric) 1 2 3 4 5

Nut Holder Fan hub Belt pulley Washer

6 7 8 9 10

Socket head screw External hex bolt Fan wheel Fan clutch External hex bolt

Unscrew external hex bolt 10 from holder 2.

Unscrew fan clutch 9 from fan hub 3.

Unscrew external hex bolt 7.

Disconnect fan wheel 8 from fan hub 3.

Unscrew socket head screw 6.

Remove washer 5.

Remove belt pulley 4.

Remove fan hub 3.

Removing the fan drive Make sure that the following prerequisites are met: The V-ribbed belt is removed. (For more information see: Checking the (optional) fan drive belt drive, page 77.)

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Preliminary work

Fig. 71: Fan drive via belt 1 2 3 4

External hex bolt Console Spacer Spacer

5 6 7

External hex bolt (4x) Belt pulley External hex bolt

Unscrew external hex bolt 7.

Remove belt pulley 6.

Unscrew external hex bolt 5.

Unscrew external hex bolt 1.

Remove console 2.

Remove spacer 3.

Remove spacer 4.

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Maintenance Preliminary work

Removing the cover (two-piece)

Fig. 72: Removing the cover (two-piece) 1 2 3

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

4 5 6

Cover Spacer (1x) Spacer (3x)

Unscrew external hex bolt 1.

Unscrew external hex bolt 2.

Unscrew external hex bolt 3.

Remove cover 4.

Remove spacer 5.

Remove spacer 6.

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Preliminary work

Fig. 73: Removing the cover 1 2

External hex bolt (2x) Cover

3

Nut (3x)

Unscrew external hex bolt 1.

Remove cover 2.

Unscrew nut 3.

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Maintenance Preliminary work

Removing the cover (one-piece)

Fig. 74: Removing the cover (one-piece) 1 2 3

External hex bolt (3x) External hex bolt (2x) Cover

4 5

Spacer (1x) Spacer (2x)

Unscrew external hex bolt 1.

Unscrew external hex bolt 2.

Remove cover 3.

Remove spacer 4.

Remove spacer 5.

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Diesel engine

5.3 Diesel engine 5.3.1 Checking the V-ribbed belt for damage Make sure that the following prerequisites are met: Fan drive is removed (if present). (For more information see: Removing the fan, page 66.) (For more information see: Removing the fan, page 67.) (For more information see: Removing the fan drive, page 67.)

Cover is removed (if present). (For more information see: Removing the cover (two-piece), page 69.) (For more information see: Removing the cover (one-piece), page 71.)

Engine is in maintenance position. (For more information see: 5.2.1 Bringing the engine into maintenance position, page 66.)

Fig. 75: Damages to V-ribbed belt Possible damages to the V-ribbed belt are: – Brittle ribs – Rubber lumps on the bottom of the belt – Dirt deposits – Stone deposits – Ribs detached from the bottom of the belt – Transverse cracks on the back – Transverse cracks in multiple ribs Check V-ribbed belt for damage.

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

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

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Maintenance Diesel engine

Fig. 76: Tension pulley (self-tensioning) 1

Tension pulley (self-tensioning)

Checking the (optional) fan drive V-ribbed belt tension

Fig. 77: Checking the fan belt for tension 1

Measuring point for frequency measurement

2

V-ribbed belt

Let engine run for 30 min at an idle.

Turn off engine.

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Diesel engine

For measurement with mobile phone: Install Easy Tension application from Hutchinson on mobile phone.

Keep frequency meter 10 mm away from measuring point 1. or Keep mobile phone microphone 10 mm away from measuring point 1.

Use index finger or a screwdriver to make V-ribbed belt 2 vibrate.

Measure tension of V-ribbed belt 2 with frequency meter at measuring point 1. or Measure tension of V-ribbed belt 2 with mobile phone with Easy Tension application from Hutchinson at measuring point 1.

Tension types

Frequency control at 20 ±5 C° [Hz]

Minimum tension

141

Normal tension

164

Maximum tension

185

Tab. 14: V-ribbed belt tension values If the measured frequency is not within the tolerance: Check V-ribbed belt 2 for damage.

If the V-ribbed belt 2 is damaged: Replace V-ribbed belt 2.

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Maintenance Diesel engine

Checking the (optional) air conditioning compressor V-ribbed belt tension

Fig. 78: Checking the V-ribbed belt for tension 1

Measuring point for frequency meter

2

V-ribbed belt

Let engine run for 30 min at an idle.

Turn off engine.

For measurement with mobile phone: Install Easy Tension application from Hutchinson on mobile phone.

Keep frequency meter 10 mm away from measuring point 1. or Keep mobile phone microphone 10 mm away from measuring point 1.

Use index finger or a screwdriver to make V-ribbed belt 2 vibrate.

Measure tension of V-ribbed belt 2 with frequency meter at measuring point 1. or Measure tension of V-ribbed belt 2 with mobile phone with Easy Tension application from Hutchinson at measuring point 1.

Tension types

Frequency control at 20 ±5 C° [Hz]

Minimum tension

87

Normal tension

107

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Tension types

Frequency control at 20 ±5 C° [Hz]

Maximum tension

126

Tab. 15: V-ribbed belt tension values If the measured frequency is not within the tolerance: Check V-ribbed belt 2 for damage.

If the V-ribbed belt 2 is damaged: Replace V-ribbed belt 2.

5.3.3 Checking the belt drive Make sure that the following prerequisites are met: – Fan drive is removed (if present). (For more information see: Removing the fan, page 66.) (For more information see: Removing the fan, page 67.) (For more information see: Removing the fan drive, page 67.)

– Cover is removed (if present). (For more information see: Removing the cover (two-piece), page 69.) (For more information see: Removing the cover (one-piece), page 71.)

– Engine is in maintenance position. (For more information see: 5.2.1 Bringing the engine into maintenance position, page 66.)

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Maintenance Diesel engine

Checking the (optional) fan drive belt drive Removing the V-ribbed belt

Fig. 79: Fan drive 1 2

V-ribbed belt External hex bolt

3 4

Internal square Tension pulley (static)

Attach the 1/2” socket wrench transition piece (external square) with lever to the internal square 3 of the tension pulley (static) 4.

Move tension pulley (static) 4 slightly counterclockwise to relieve the external hex bolt 2.

Release external hex bolt 2.

Turn tension pulley (static) 4 clockwise.

Remove V-ribbed belt 1.

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Diesel engine

Checking the belt drive

Fig. 80: Fan drive belt drive 1 2

Belt pulley on crankshaft Fan belt pulley

3

Tension pulley (static)

Check components for damage.

If components are damaged: Do not start engine.

Replace defective components, see repair instruction.

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Maintenance Diesel engine

Installing the V-ribbed belt

Fig. 81: Installing the V-ribbed belt 1 2

V-ribbed belt External hex bolt

3 4

Internal square Tension pulley (static)

Install new V-ribbed belt 1.

Move tension pulley (static) 4 slightly counterclockwise to enable tightening of the external hex bolt 2.

Tighten external hex bolt 2.

Remove the 1/2” socket wrench transition piece (external square) with lever from the internal square 3 of the tension pulley (static) 4.

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Diesel engine

Checking the alternator belt drive Removing the V-ribbed belt

Fig. 82: Replacing the V-ribbed belt 1 2

Internal square V-ribbed belt

3

Tension pulley (self-tensioning)

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

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

The V-ribbed belt 2 is relaxed.

Remove V-ribbed belt 2.

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

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Maintenance Diesel engine

Checking the alternator belt drive

Fig. 83: Checking the alternator belt drive 1 2 3

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

4 5

Coolant pump Belt pulley on the crankshaft

Check components for damage.

If components are damaged: Do not start engine.

Replace defective components, see repair instruction.

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Diesel engine

Installing the V-ribbed belt

Fig. 84: Installing the V-ribbed belt 1 2

Internal square V-ribbed belt

3

Tension pulley (self-tensioning)

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

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

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

The V-ribbed belt 2 is tensioned.

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Maintenance Diesel engine

Checking the alternator belt drive Removing the alternator V-ribbed belt

Fig. 85: Removing the V-ribbed belt 1 2

Internal square V-ribbed belt

3

Tension pulley (self-tensioning)

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

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

The V-ribbed belt 2 is relaxed.

Remove V-ribbed belt 2.

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

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

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Diesel engine

Checking the alternator belt drive

Fig. 86: Checking the alternator belt drive 1 2 3

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

4 5

Alternator Coolant pump belt pulley

Check components for damage.

If components are damaged: Do not start engine.

Replace defective components.

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Maintenance Diesel engine

Installing the alternator V-ribbed belt

Fig. 87: Installing the V-ribbed belt 1 2

Internal square V-ribbed belt

3

Tension pulley (self-tensioning)

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

Install V-ribbed belt 2.

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

The V-ribbed belt 2 is tensioned.

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Diesel engine

Checking the (optional) air conditioning compressor belt drive Removing the V-ribbed belt

Fig. 88: Removing the V-ribbed belt 1 2

Tension pulley (self-tensioning) Internal square

3

V-ribbed belt

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

Swivel back tension pulley (self-tensioning) 1 counterclockwise against the spring force to the limit stop.

The V-ribbed belt 3 is free.

Remove the V-ribbed belt 3.

Turn back tension pulley (self-tensioning) 1.

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Maintenance Diesel engine

Checking the air conditioning compressor belt drive

Fig. 89: Components 1 2 3

Viscous damper belt pulley Tension pulley (self-tensioning) Alternator belt pulley

4 5 6

Air conditioning compressor belt pulley Deflection pulley Coolant pump belt pulley

Check components for damage.

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

Replace damaged components, see repair instruction.

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Diesel engine

Installing the V-ribbed belt

Fig. 90: Installing the V-ribbed belt 1 2

Tension pulley (self-tensioning) Internal square

3

V-ribbed belt

Swivel back tension pulley (self-tensioning) 1 counterclockwise against the spring force to the limit stop.

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

Turn tension pulley (self-tensioning) 1 carefully into the original position.

The V-ribbed belt 3 is tensioned.

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Maintenance Diesel engine

Checking the (optional) air conditioning compressor belt drive Removing the V-ribbed belt

Fig. 91: Removing the air conditioning compressor belt 1 2 3

External hex bolt Tension pulley (static) Internal square

4 5

External hex bolt V-ribbed belt

Release external hex bolt 1.

Release external hex bolt 4.

Turn tension pulley (static) 2 at the internal square 3 counterclockwise.

Unscrew external hex bolt 4.

Release tension pulley (static) 2.

Remove V-ribbed belt 5.

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Diesel engine

Checking the belt drive

Fig. 92: Air conditioning compressor belt drive 1 2

Tension pulley (static) Belt pulley on air conditioning compressor

3

Belt pulley on crankshaft

Check components for worn bearings.

If parts are damaged: Do not start engine.

Replace defective parts, see repair instruction.

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Maintenance Diesel engine

Installing the V-ribbed belt

Fig. 93: Removing the air conditioning compressor belt 1 2 3

External hex bolt Tension pulley (static) Internal square

4 5

External hex bolt V-ribbed belt

Install V-ribbed belt 5.

Turn tension pulley (static) 2 at the internal square 3 counterclockwise.

Screw in external hex bolt 4.

Turn back tension pulley (static) 2.

Tighten external hex bolt 1.

Tighten external hex bolt 4.

The V-ribbed belt 5 is tensioned.

5.3.4 Replacing the belt drive Make sure that the following prerequisites are met: – Fan drive is removed (if present). (For more information see: Removing the fan, page 66.) (For more information see: Removing the fan, page 67.) (For more information see: Removing the fan drive, page 67.)

– Cover is removed (if present). (For more information see: Removing the cover (two-piece), page 69.) (For more information see: Removing the cover (one-piece), page 71.)

– Engine is in maintenance position. (For more information see: 5.2.1 Bringing the engine into maintenance position, page 66.)

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Maintenance

Operator's manual

Diesel engine

Replacing the (optional) fan drive belt drive Removing the belt drive

Fig. 94: Removing the fan drive belt drive 1 2 3 4

External hex bolt External hex bolt Tension pulley V-ribbed belt

5 6 7

Fan belt pulley Crankshaft belt pulley Internal square

Unscrew external hex bolt 1.

Release external hex bolt 2.

Remove V-ribbed belt 4.

Unscrew external hex bolt 2.

Remove tension pulley 3.

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Maintenance Diesel engine

Installing the belt drive

Fig. 95: Installing the fan drive belt drive 1 2 3 4

External hex bolt External hex bolt Tension pulley V-ribbed belt

5 6 7

Fan belt pulley Crankshaft belt pulley Internal square

Install new tension pulley 3.

Screw in external hex bolt 2.

Install new V-ribbed belt 4.

Turn tension pulley 3 slightly counterclockwise.

Screw in external hex bolt 1.

Tighten external hex bolt 2.

Tighten external hex bolt 1.

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Maintenance

Operator's manual

Diesel engine

Replacing the alternator belt drive Removing the V-ribbed belt

Fig. 96: Removing the V-ribbed belt 1 2

Internal square V-ribbed belt

3

Tension pulley (self-tensioning)

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

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

The V-ribbed belt 2 is relaxed.

Remove V-ribbed belt 2.

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

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Operator's manual

Maintenance Diesel engine

Replacing the belt drive

Fig. 97: Replacing the belt drive 1 2 3

Tension pulley (self-tensioning) Sleeve Deflection pulley

4 5

External hex bolt External hex bolt

Unscrew external hex bolt 4.

Remove deflection pulley 3.

Remove sleeve 2.

Unscrew external hex bolt 5.

Remove tension pulley (self-tensioning) 1.

Install new tension pulley (self-tensioning) 1.

Tighten external hex bolt 5.

Install sleeve 2.

Install new deflection pulley 3.

Tighten external hex bolt 4.

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Maintenance

Operator's manual

Diesel engine

Installing the V-ribbed belt

Fig. 98: Installing the V-ribbed belt 1 2

Internal square V-ribbed belt

3

Tension pulley (self-tensioning)

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

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

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

The V-ribbed belt 2 is tensioned.

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Maintenance Diesel engine

Replacing the alternator belt drive Removing the V-ribbed belt

Fig. 99: Removing the V-ribbed belt 1 2

Internal square V-ribbed belt

3

Tension pulley

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

Turn back the tension pulley 3 at the internal square 1 counterclockwise against the spring force to the limit stop.

The V-ribbed belt 2 is relaxed.

Remove V-ribbed belt 2.

Carefully turn back the tension pulley 3 at the internal square 1 clockwise to the limit stop.

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Maintenance

Operator's manual

Diesel engine

Removing the belt drive

Fig. 100: Removing the belt drive 1 2

External hex bolt (2x) Deflection pulley (2x)

3 4

Tension pulley External hex bolt

Unscrew external hex bolt 1.

Remove deflection pulley 2.

Unscrew external hex bolt 4.

Remove tension pulley 3.

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Operator's manual

Maintenance Diesel engine

Installing the belt drive

Fig. 101: Installing the belt drive 1 2

External hex bolt (2x) Deflection pulley (2x)

3 4

Tension pulley External hex bolt

Install new tension pulley 3.

Tighten external hex bolt 4.

Install new deflection pulley 2.

Tighten external hex bolt 1.

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Maintenance

Operator's manual

Diesel engine

Installing the V-ribbed belt

Fig. 102: Installing the V-ribbed belt 1 2

Internal square V-ribbed belt

3

Tension pulley

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

Turn back the tension pulley 3 at the internal square 1 counterclockwise against the spring force to the limit stop.

Install V-ribbed belt 2.

Carefully turn back the tension pulley 3 at the internal square 1 clockwise to the limit stop.

The V-ribbed belt 2 is tensioned.

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Maintenance Diesel engine

Replacing the (optional) air conditioning compressor belt drive Removing the V-ribbed belt

Fig. 103: Replacing the V-ribbed belt 1 2

Tension pulley Internal square

3

V-ribbed belt

Turn tension pulley 1 at the internal square 2 counterclockwise to the limit stop.

Remove V-ribbed belt 3.

Turn back tension pulley 1.

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Maintenance

Operator's manual

Diesel engine

Replacing the deflection pulleys and tension pulley

Fig. 104: Replacing the deflection pulleys and tension pulley 1 2

Tension pulley Deflection pulley

3 4

External hex bolt External hex bolt

Unscrew external hex bolt 3.

Remove deflection pulley 2.

Unscrew external hex bolt 4.

Remove tension pulley 1.

Install new tension pulley 1.

Tighten external hex bolt 4.

Install new deflection pulley 2.

Tighten external hex bolt 3.

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Maintenance Diesel engine

Installing the V-ribbed belt

Fig. 105: Replacing the V-ribbed belt 1 2

Tension pulley Internal square

3

V-ribbed belt

Turn tension pulley 1 at the internal square 2 counterclockwise to the limit stop.

Install V-ribbed belt 3.

Turn back tension pulley 1.

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Maintenance

Operator's manual

Diesel engine

Replacing the (optional) air conditioning compressor belt drive Removing the V-ribbed belt

Fig. 106: Removing the air conditioning compressor belt 1 2 3

External hex bolt Tension pulley (static) Internal square

4 5

External hex bolt V-ribbed belt

Release external hex bolt 1.

Release external hex bolt 4.

Turn tension pulley (static) 2 at the internal square 3 counterclockwise.

Unscrew external hex bolt 4.

Release tension pulley (static) 2.

Remove V-ribbed belt 5.

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Maintenance Diesel engine

Replacing the tension pulley

Fig. 107: Removing the tension pulley 1

External hex bolt

2

Tension pulley

Unscrew external hex bolt 1.

Remove tension pulley 2.

Install new tension pulley 2.

Screw in external hex bolt 1.

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Maintenance

Operator's manual

Diesel engine

Installing the V-ribbed belt

Fig. 108: Removing the air conditioning compressor belt 1 2 3

External hex bolt Tension pulley (static) Internal square

4 5

External hex bolt V-ribbed belt

Install V-ribbed belt 5.

Turn tension pulley (static) 2 at the internal square 3 counterclockwise.

Screw in external hex bolt 4.

Turn back tension pulley (static) 2.

Tighten external hex bolt 1.

Tighten external hex bolt 4.

The V-ribbed belt 5 is tensioned.

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

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Maintenance Diesel engine

5.3.6 Checking the intake system for leaks and damage

Fig. 109: Checking the intake system 1 2 3

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

4 5

Air intake pipe Heating flange

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

Check components for damage.

Check components for leaks.

Check components for tight fit.

If components are damaged: Do not start engine.

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

Replace damaged components, see repair manual.

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Maintenance

Operator's manual

Diesel engine

5.3.7 Checking the exhaust system

Fig. 110: Components to be checked 1 2 3

Exhaust gas stub Exhaust manifold seal Exhaust manifold

4 5

Exhaust gas turbocharger Engine brake flap actuator

Check components for damage.

Check components for leaks.

Check components for tight fit.

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

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

If components are damaged: Do not start engine.

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

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Maintenance Engine oil system

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

Serious burns possible.

Let the engine cool down to ambient temperature.

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

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

Damage to health and environmental damage possible.

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

Make sure that no lubricant gets into the environment.

Observe national and international guidelines for disposal.

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Maintenance

Operator's manual

Engine oil system

Fig. 111: Checking the engine oil system 1

Oil cooler

6

2 3 4 5

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

7 8 9

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

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Operator's manual

Maintenance Engine oil system

Fig. 112: Checking the engine oil system 1 2 3

Oil line from oil separator to oil pan Oil dipstick Supply line from crankcase ventilation to oil separator

4 5

Oil separator Oil level sensor

Check components for leaks.

Check components for damage.

Check components for proper fastening.

Check oil loss at other components.

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

Determine cause and rectify.

Replace defective parts, see repair manual.

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Maintenance

Operator's manual

Engine oil system

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

Damage to health and environmental damage possible.

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

Make sure that no lubricant gets into the environment.

Observe national and international guidelines for disposal.

Fig. 113: Checking the engine oil level 1 2

Oil filler neck cover Oil filler neck

3

Oil dipstick

Start the engine.

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

Wait 5 minutes.

Pull out the oil dipstick 3.

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

Insert oil dipstick 3.

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Maintenance Engine oil system

Pull out the oil dipstick 3.

Fig. 114: Oil dipstick 1

Maximum

2

Minimum

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

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

If the oil level is below the Minimum 2 mark: Refill the oil. (For more information see: Filling the engine oil, page 118.)

Insert oil dipstick 3.

Check oil level again.

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

The engine is turned off.

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

A suitable drain hose is available.

A suitable collection container is available.

Engine oil is available.

Engine oil specification (For more information see: 5.11.2 Engine oils for diesel engines with emission limit stage Tier 4 Final, page 162.)

Draining the engine oil Graphic representation

Description

Required number

Identification number

Drain hose

1

12690422

Drain hose 90°

1

12690423

Tab. 16: Special tool

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Maintenance

Operator's manual

Engine oil system

WARNING Hot components on the engine!

Serious burns possible.

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

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

Damage to health and environmental damage possible.

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

Make sure that no lubricant gets into the environment.

Observe national and international guidelines for disposal.

Fig. 117: Draining the engine oil 1 2

Oil drain plug (optional) Oil drain valve

3 4

Sealing cap Drain hose

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

Unscrew oil drain plug 1 (optional).

Let engine oil run into the collection container.

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Maintenance Engine oil system

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

-

Locking agent

-

Part contact surfaces

-

Screws

Reusable

Stage

Tightening torque

1.

27 Nm

Tab. 17: Tightening instruction Tighten oil drain plug 1 (optional) according to tightening instruction.

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

Put a collection container under the oil drain valve 2.

Unscrew sealing cap 3 from oil drain valve 2.

Install drain hose 4 on oil drain valve 2.

Oil drain valve 2 is opened.

Engine oil runs out.

Remove drain hose 4.

Tighten sealing cap 3 on oil drain valve 2.

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

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

Serious burns possible.

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

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

Damage to health and environmental damage possible.

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

Make sure that no lubricant gets into the environment.

Observe national and international guidelines for disposal.

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Maintenance

Operator's manual

Engine oil system

Fig. 119: Removing the oil filter 1

Nozzle (2x)

2

Oil filter (2x)

Unscrew oil filter 2.

Cleaning Clean sealing surface with a lint-free cloth.

Installing the oil filter WARNING Hot components on the engine!

Serious burns possible.

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

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Maintenance Engine oil system

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

Damage to health and environmental damage possible.

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

Make sure that no lubricant gets into the environment.

Observe national and international guidelines for disposal.

Fig. 120: Installing the oil filter 1

Nozzle (2x)

2

Oil filter (2x)

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

Screw on new oil filter 2.

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Maintenance

Operator's manual

Engine oil system

Tightening instruction for M30 x 2 oil filter Lubricant

-

Locking agent

-

Part contact surfaces

Engine oil

Screws

-

Stage

Tightening torque

1.

Screw on by hand until the seal is in contact

2.

3/4 - 1 revolution (20 ±5 Nm)

Tab. 18: Tightening instruction Tighten new oil filter 2 according to the tightening instruction.

Filling the engine oil

Fig. 122: Filling the engine oil (example filling on cylinder head cover) 1 2

Oil filler neck Oil filler cap

3

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Oil dipstick

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Operator's manual

Maintenance Engine oil system

Unscrew oil filler cap 2.

Fill oil via oil filler neck 1.

Check engine oil level. (For more information see: 5.4.2 Checking the engine oil level, page 112.)

Insert oil dipstick 3.

Check oil level again.

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

Clean oil filler cap 2.

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

Start the engine.

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

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

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

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

Serious burns possible.

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

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

Damage to health and environmental damage possible.

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

Make sure that no lubricant gets into the environment.

Observe national and international guidelines for disposal.

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Maintenance

Operator's manual

Engine oil system

Fig. 123: Removing the housing cover 1

Housing cover

2

Screwdriver

Open housing cover 1 with a screwdriver 2.

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Maintenance Engine oil system

Fig. 124: Replacing the oil separator filter insert 1 2

Oil separator filter housing Oil separator filter insert

3

Housing cover

Remove housing cover 3.

Remove oil separator filter insert 2.

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

Serious burns possible.

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

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Maintenance

Operator's manual

Engine oil system

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

Damage to health and environmental damage possible.

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

Make sure that no lubricant gets into the environment.

Observe national and international guidelines for disposal.

Fig. 125: Replacing the oil separator filter insert 1 2

Oil separator filter housing Oil separator filter insert

3

Housing cover

Install new oil separator filter insert 2.

Tighten housing cover 3 by hand.

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

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Maintenance Cylinder head

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

Fig. 126: Cylinder head cover 1 2 3 4

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

5 6 7

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

Disconnect the electrical line from the electrical plug connection 4.

Unscrew the external hex bolt 3.

Unscrew the external hex bolts 1.

Remove the cylinder head cover 2.

Release the hex nuts 7.

Remove the seal 5.

Repeat the process for all cylinder head covers.

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Cylinder head

Checking and cleaning Check seal 5 for damage.

Clean the sealing surface of the cylinder head cover 2.

Clean the sealing surface of the cylinder head.

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

Removing the locking part

Fig. 127: Removing the locking part 1 2

Flywheel housing opening Locking part

3

External hex bolt

Unscrew external hex bolt 3.

Remove locking part 2.

Installing the turning device on the flywheel housing Graphic representation

Description

Required number

Identification number

Turning device

1

0524045

Tab. 19: Special tool

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Maintenance Cylinder head

Fig. 129: Installing the turning device on the flywheel housing 1 2

Flywheel housing Turning device

3

External hex bolt (3x)

Install turning device 2 on flywheel housing 1.

Tighten external hex bolt 3.

Installing the turning device on the belt pulley Graphic representation

Description

Required number

Identification number

Turning device

1

10116805

Tab. 20: Special tool

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Operator's manual

Cylinder head

Fig. 131: Installing the turning device on the belt pulley 1 2

Cylinder screw (6x) Turning device

3

Belt pulley

Install turning device 2 on belt pulley 3.

Tighten cylinder screw 1.

Installing the turning device on the crankshaft Graphic representation

Description

Required number

Identification number

Turning device

1

10118801

Tab. 21: Special tool

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Maintenance Cylinder head

Fig. 133: Installing the turning device on the crankshaft 1

Turning device

2

Crankshaft

Turning device 1 on crankshaft 2

Installing the auxiliary output 4 turning device Graphic representation

Description

Required number

Identification number

Turning device

1

10134822

Tab. 22: Special tool

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Operator's manual

Cylinder head

Fig. 135: Removing the locking part 1

External hex bolt

2

Locking part

2

Turning device

Unscrew external hex bolt 1.

Remove locking part 2.

Fig. 136: Installing the turning device 1

Socket head screws Install turning device 2 Tighten socket head screws 1.

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Maintenance Cylinder head

Installing the auxiliary output 2 turning device Graphic representation

Description

Required number

Identification number

Turning device

1

10138480

Tab. 23: Special tool

Fig. 138: Removing the locking part 1

Locking part

2

External hex bolt

Unscrew external hex bolt 2.

Remove locking part 1.

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Maintenance

Operator's manual

Cylinder head

Fig. 139: Installing the turning device 1

Turning device

2

Socket head screw

Install turning device 1.

Tighten socket head screw 2.

Setting the cylinder to top dead center (TDC) One cylinder is always in ignition TDC position and one cylinder is in overlapping TDC position at the same time.

TDC type

Ignition TDC

Overlapping TDC

Position of the piston

between “compressing” and “working” cycles

between “ejection” and “suction” cycles

Position of the valves

closed

overlapping

Rocker arms

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

Rocker arm movable by hand.

Yes

No

Setting valve clearance possible.

Yes

No

Tab. 24: Differences between ignition TDC and overlapping TDC

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Maintenance Cylinder head

Fig. 140: Valve overlap

Fig. 141: TDC marks: Ignition TDC for cylinder 1 1

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

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Cylinder head

TDC marking on the flywheel and flywheel housing 1 align.

Cylinder 1 is in ignition TDC position.

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

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

Valves of the cylinder set (ignition TDC)

1 5 3 6 2 4

overlap (overlapping TDC) 6 2 4 1 5 3 Tab. 25: Valves of the cylinder

Setting cylinder 1 to ignition TDC

Fig. 142: TDC marks: Ignition TDC for cylinder 1 1

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

TDC marking on the flywheel and flywheel housing 1 align.

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Maintenance Cylinder head

Cylinder 1 is in ignition TDC position.

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

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

Check if the cylinder rocker arm can be moved by hand.

The cylinder rocker arm can be moved by hand.

Cylinder is in ignition TDC position.

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

Checking and setting the valve clearance for the inlet valve and outlet valve Make sure that the following prerequisites are met: The engine is in the maintenance position. (For more information see: 5.2.1 Bringing the engine into maintenance position, page 66.)

The cylinder head covers are removed.

The cylinder to be checked is at ignition TDC.

Description

Unit Value

Valve clearance, inlet, cold

mm 0.3

Valve clearance, outlet, cold

mm 0.4

Fig. 143: Check the valve clearance. Setting the valve clearance 1

Feeler gauge

5

Adjusting screw

See next page for continuation of the image legend

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Cylinder head

2 3 4

Valve bridge Lock nut Allen wrench

6 7

Tappet Torque wrench

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

Check the valve clearance.

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

Correct the setting by turning the adjusting screw 5.

Hold onto the adjusting screw 5.

Tensioning instruction for M10X1-6G6H lock nut Lubricant

-

Locking agent

-

Part contact surfaces

-

Screws

Reusable

Stage

Tightening torque

1.

45 Nm

Tab. 26: Tensioning instruction Tighten the lock nut 3 according to the tensioning instruction.

Check the setting again.

Repeat the process for all cylinders.

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

Checking and setting the valve clearance for the outlet valve with auxiliary brake system (ABS) (optional) Setting the valve clearance for the inlet valve: (For more information see: Checking and setting the valve clearance for the inlet valve and outlet valve, page 133.)

Make sure that the following prerequisites are met: The engine is in the maintenance position. (For more information see: 5.2.1 Bringing the engine into maintenance position, page 66.)

The cylinder head covers are removed.

The cylinder to be checked is at ignition TDC. Description

Unit Value

Valve clearance, inlet, cold

mm 0.3

Valve clearance, outlet, cold

mm 0.6

Auxiliary brake system, cold

mm 0.4

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Maintenance Cylinder head

Fig. 145: Checking and setting the valve clearance on the ABS outlet valve (optional) 1 2 3 4 5

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

6 7

ABS lock nut Counterholder

8 9

Measuring point for feeler gauge on ABS ABS piston

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

Release the rocker arm lock nut 3.

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

Release the ABS lock nut 6.

Unscrew the ABS adjusting screw 5.

The ABS adjusting screw 5 disappears into the counterholder 7.

Press on the ABS valve bridge 1 with your hand.

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

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

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

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

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

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

ABS piston 9 goes to the limit stop.

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

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Cylinder head

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

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

Press on the ABS valve bridge 1 with your hand.

ABS piston 9 goes to the limit stop.

The push rod has play.

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

Repeat the process for all cylinders.

Installing the locking part

Fig. 146: Installing the locking part 1 2

Flywheel housing opening Locking part

3

External hex bolt

Install locking part 2.

Tighten external hex bolt 3.

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Maintenance Cylinder head

Installing the cylinder head cover

Fig. 147: Cylinder head cover 1 2 3 4

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

5 6 7

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

Install the cylinder head cover seal 5.

Connect the electrical connection for the injector 6.

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Cylinder head

Tensioning instruction for M4 hex nut Lubricant

-

Locking agent

-

Part contact surfaces

-

Screws

-

Stage

Tightening torque

1.

1.8 Nm

Tab. 27: Tightening instruction 12977315_000 Tighten the hex nuts 7 according to the tensioning instruction.

Install the cylinder head cover 2.

Tighten the external hex bolts 1.

Tighten the external hex bolt 3.

Connect the electrical line to the electrical plug connection 4.

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Maintenance Cooling system

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

Serious burns possible.

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

Wear protective gloves and safety goggles.

Fig. 149: Components to be checked 1 2 3 4 5 6

Coolant outlet Coolant cooler supply Coolant pump Compensation tank return Cylinder head gasket Coolant ventilation

7 8 9 10 11 12

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

Check components for leaks.

Check components for damage.

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

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Cooling system

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

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

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

Replace damaged components, see repair manual.

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

Serious burns possible.

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

Wear protective gloves and safety goggles.

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

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

Refill the coolant, see documentation from the device manufacturer. (For more information see: 5.6.3 Checking the concentration of the antifreeze agent in the coolant, page 140.) (For more information see: Filling the coolant, page 144.)

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

Serious burns possible.

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

Wear protective gloves and safety goggles.

Open the sealing cap on the filler neck.

Take a coolant sample.

Analyze the sample using a suitable test method.

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

Correcting the concentration of the antifreeze agent If necessary, calculate the missing quantity of antifreeze agent according to the calculation formula (see: fig. 150, page 141).

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Maintenance Cooling system

NOTICE Concentration of the antifreeze agent too high!

Damage to engine.

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

50

29

50

-

29

=

21

100

-

29

=

71

x

50

:

71

=

14,8

Fig. 150: Calculation formula for refilling quantity of antifreeze agent, example 29 vol.% 1

Coolant fill quantity in liters

2

Measured concentration in vol. %

3

Refilling quantity of antifreeze agent in liters

Drain the calculated refilling quantity from the cooling system.

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

Fill the calculated refilling quantity of the antifreeze agent.

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

– A collection container with the necessary capacity is available.

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

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

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

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

A collection container with the necessary capacity is available.

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

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

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Cooling system

Graphic representation

Description

Required number

Identification number

Drain hose

1

12690422

Drain hose 90°

1

12690423

Tab. 28: Special tool DANGER Hot cooler parts and hot coolant!

Serious burns possible.

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

Wear protective gloves and safety goggles.

NOTICE Escaping coolant!

Injuries Avoid skin contact with coolant.

Follow the manufacturer's instructions.

When mixing coolant, wear rubber gloves and safety goggles.

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

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Maintenance Cooling system

Fig. 153: Draining the coolant on the oil cooler 1 2

Protecting cap Drain valve

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3

Drain hose

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Cooling system

Fig. 154: Draining the coolant on the coolant manifold 1 2

Protecting cap Drain valve

3

Drain hose

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

Excess pressure escapes from the cooling system.

Unscrew protecting cap 1.

Connect drain hose 3 to the drain valve 2.

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

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

Filling the coolant Fill the coolant via the device side filler neck. (For more information see: Correcting the concentration of the antifreeze agent, page 140.)

Fill cooling system up to maximum.

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

Start the engine.

Let the engine warm up.

Coolant temperature > 80 °C. Turn off engine. (For more information see: 4.3 Turning off the engine, page 62.)

Let the engine cool down.

Check coolant level. (For more information see: 5.6.2 Checking the coolant level, page 140.)

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

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Maintenance Fuel system

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

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

Reduce the pressure to below 10 bar with diagnostics software.

Check the residual pressure with diagnostics software.

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

Do not open any fuel connections that are under pressure.

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

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

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

Fig. 155: Components 1 2

Fuel high pressure pump Injection lines

5 6

3 4

Fuel fine filter Fuel fine filter console

7

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

Check components for damage.

Check components for proper fastening.

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Fuel system

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

Check tank lid, see documentation from the device manufacturer.

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

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

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

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

NOTICE Dirt!

Damage to Common Rail System.

Make sure that no dirt gets onto the clean side of the filter.

Do not reuse the fuel filter.

Observe instructions for work on the Common Rail System.

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

Ventilate the fuel system. (For more information see: 5.7.5 Ventilating the fuel system, page 149.)

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

Wait 20 minutes.

Check pressure reduction with diagnostics software (variables: 6996 - Fuel Pressure High 1/ 6997 - Fuel Pressure High 2). (For more information see: 7.1.3 Diagnostic tools, page 172.)

Pressure below 10 bar

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

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NOTICE Dirt!

Damage to Common Rail System.

Make sure that no dirt gets onto the clean side of the filter.

Do not reuse the fuel filter.

Observe instructions for work on the Common Rail System.

Fig. 156: Removing the fuel fine filter 1

Fuel fine filter (2x)

2

Fuel fine filter console

If the engine is running: Turn off engine.

Wait 20 minutes.

Check pressure reduction with diagnostics software (variables: 6996 - Fuel Pressure High 1/ 6997 - Fuel Pressure High 2). (For more information see: 7.1.3 Diagnostic tools, page 172.)

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

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

Clean the fuel fine filter console 2 and surrounding area.

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

Dispose of old fuel fine filter properly.

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Fuel system

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

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

Installing the fuel fine filter NOTICE Dirt!

Damage to Common Rail System.

Make sure that no dirt gets onto the clean side of the filter.

Do not reuse the fuel filter.

Observe instructions for work on the Common Rail System.

Fig. 157: Installing the fuel fine filter 1

Fuel fine filter (2x)

2

Fuel fine filter console

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

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Maintenance Fuel system

Tightening instruction for fuel fine filter SW 30 unlocking hex Lubricant

-

Locking agent

-

Part contact surfaces

Engine oil

Screws

-

Stage

Tightening torque

1.

Screw on by hand until the seal is in contact

Stage

Angle of rotation

2.

Tighten by hand 3/4 of a revolution

Tab. 29: Tightening instruction Tighten new fuel fine filter 1 according to the tightening instruction.

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

Ventilate the fuel system. (For more information see: 5.7.5 Ventilating the fuel system, page 149.)

5.7.5 Ventilating the fuel system

3

1

2

4

5

6

Fig. 159: Fuel diagram, external system 1 2 3

Connection to engine Fuel air cooler (optional) Fuel prefilter

4 5 6

Water separator Manual ventilation pump Fuel tank

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

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

Wait 1 minute.

Pressure escapes through ventilation.

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

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Fuel system

Wait until the pressure has been relieved through ventilation.

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

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Maintenance Air filter

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

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

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

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

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Electrical system

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

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

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

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

5.9.3 Checking the engine control unit bearings for damage

Fig. 160: Engine control unit mounting 1

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

Check engine control unit bearings 1 for tight fit.

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

Replace bearings, see repair manual.

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Maintenance Electrical system

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

Damage to plug connections.

Leave plug connections plugged in during the visual inspection.

Fig. 161: Sensors 1 2 3

Speed sensor Pressure sensor Pressure sensor

4 5 6

Pressure sensor Temperature sensor Temperature sensor

Check components for tight fit.

Check components for damage.

Check components for abrasion-free laying.

Check components for proper fastening.

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

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

Replace defective components, see repair instruction.

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Electrical system

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

Fig. 162: Checking the heating flange 1 2

Heating flange Ground

3

Positive pole

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

Disconnect the negative cable from the battery.

Disconnect the electrical connection cable from the positive pole 3.

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

Measure the resistance.

If the resistance at 20 °C falls below 230 ±23 mOhm: Check the heating flange for sooting. (For more information see: Checking the heating flange for sooting, page 155.)

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Maintenance Electrical system

Checking the heating flange for sooting

Fig. 163: Checking the heating flange for sooting 1 2 3

Air intake pipe (example) Ground Positive pole

4 5

External hex bolt Heating flange

Disconnect the electrical connection cable from the positive pole 3.

Unscrew external hex bolt 4.

Remove heating flange 5.

NOTICE Undiscovered damage on the exhaust gas turbocharger!

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

Check the exhaust gas turbocharger for oil loss.

Check heating flange 5 for sooting.

Check the air intake pipe 1 for sooting.

Check the air intake pipe 1 for oil residues.

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

Remove brake cleaner residues from the heating flange.

Install heating flange.

Tighten the ground 2 and positive pole 3 hex bolts according to tightening instruction.

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Electrical system

Tightening instruction for ground and positive pole M6 hex bolts Lubricant

-

Locking agent

-

Part contact surfaces

-

Screws

Reusable

Stage

Tightening torque

1.

8.5 ±1 Nm

Tab. 30: Tightening instruction Connect the ohmmeter or multimeter to the positive pole 3 and to ground 2.

Measure the resistance.

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

Connect the electrical connection cable to the positive pole 3.

Connect the negative cable to the battery.

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5.9.6 Replacing the heating flange Removing the heating flange

Fig. 165: Replacing the heating flange 1 2

Air intake pipe (example) Positive pole

3 4

External hex bolt Heating flange

Disconnect the electrical line from the positive pole 2.

Unscrew external hex bolt 3.

Remove heating flange 4.

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Electrical system

Installing the heating flange

Fig. 166: Replacing the heating flange 1 2

Air intake pipe (example) Positive pole

3 4

External hex bolt Heating flange

Install new heating flange 4.

Screw in external hex bolt 3.

Connect the electrical line to the positive pole 2.

Connect the ground line to the battery.

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Maintenance Exhaust aftertreatment system

5.10 Exhaust aftertreatment system 5.10.1 Checking the exhaust aftertreatment system for leaks and damage 5.10.2 SCROnly WARNING Production of ammonia gas when heating above 100 °C from reducing agent deposits.

Serious poisoning possible.

Before maintenance work on the exhaust system, let the engine cool down to below 100 °C. Never heat reducing agent deposits in order to remove them.

WARNING Hot components on the engine!

Serious burns possible.

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

Fig. 167: Components to be checked 1 2 3

Profile clamp Profile clamp Reduction agent injector

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4 5 6

Bracket clip Profile clamp Strap clamp

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Exhaust aftertreatment system

Check the components for leaks.

If components are leaking: Do not start the engine.

Replace components, see repair manual.

Check components for proper fastening.

If components are loose: Do not start the engine.

Tighten loose components. (For more information see: 5.10.4 SCRonly, page 160.)

Check the components for damage.

If components are damaged: Do not start the engine.

Replace damaged components, see repair manual.

5.10.3 Check components 5.10.4 SCRonly

5 7

1 6

2

3

4

4

7 8

Fig. 168: Tightening torques 1 2 3 4

Profile clamp Profile clamp Profile clamp Hinge bracket

5 6 7 8

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Bracket clip Reduction agent injector Temperature sensor/pressure sensor NOx sensor/NH3 sensor

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Maintenance Exhaust aftertreatment system

Number Part

Tightening torque

1

Profile clamp 1

23 ±2 Nm

2

Profile clamp 2

9 +2/ -1 Nm

3

Profile clamp 3

23 ±2 Nm

4

Hinge bracket 4

21 ±1 Nm

5

Bracket clip 5

23 ±2 Nm

6

Reduction agent injector 6

5 ±0.5 Nm

7

Temperature sensor/pressure sensor 7

35 +5/ -0 Nm

8

NOx sensor/NH3 sensor 8

50 ±10 Nm

Tab. 31: Tightening torques Note Check profile clamps, reduction agent injectors, and sensors for tight fit only during the first check according to the maintenance schedule.

Check components for tight fit.

If a component is loose: Tighten component with torque according to the tightening instruction.

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Lubricants and operating fluids

5.11 Lubricants and operating fluids 5.11.1 Fill quantities Name

Quantity

Engine oil

43 l - 47 l (1.5 l per filter)

Coolant (engine) 25 l Reduction agent See documentation from the device manufacturer.

Tab. 32: Fill quantities for oil change (reference values)

5.11.2 Engine oils for diesel engines with emission limit stage Tier 4 Final Liebherr products When using original Liebherr lubricant products, the longest possible change interval according to the maintenance schedule can be used.

Sulfur content in fuel in ppm to 15

Engine oil change interval 100 % (standard interval according to maintenance schedule)

Liebherr recommends the use of the following products

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

Lubricating oil specification

LH-00-ENG LA

Tab. 33: Engine oil change intervals when using Liebherr products

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

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

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

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Sulfur content in fuel in ppm

Engine oil change interval

15

50%

Lubricating oil specification

LH-00-ENG LA

Tab. 34: Change interval when using non-Liebherr products

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

Avoid combining different products.

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

Anticorrosive antifreeze agent Liebherr recommendation Type

Name

Premix ) Liebherr Antifreeze OS Mix A

Tab. 35: Recommendations for anticorrosive and antifreeze agents A)

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

Minimum requirements for the quality Specification LH-01-COL Tab. 36: Minimum requirement for the quality

Water Liebherr recommends water having the following qualities Corresponds to the guideline for drinking water from the World Health Organization (WHO) from 2006 Demineralized water (reverse osmosis water) Tab. 37: Minimum requirements for the quality

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Operator's manual

Lubricants and operating fluids

5.11.4 Fuel for diesel engines with emission limit stage Tier 4 Final Minimum requirement for the quality Approved diesel fuels according to DIN EN 590 and ASTM D975 1-D S15/2-D S15

Tier 4 final

Maximum sulfur content in the fuel

15 ppm

Lubricity at 60 °C (HFRR)

460 m

Fuel purity for tank filling according to ISO 4406:

18/17/14

Minimum cetane number

45

Tab. 38: Minimum requirement for diesel fuels Specification LH-00-FUEL Tab. 39: Minimum requirements for the quality

Reduction agent Approved reduction agent: – Reduction agent standardized according to ISO 22241 Specification LH-00-UREA Tab. 40: Minimum requirements for the quality for better results Designations: – AdBlue® in Europe – DEF (Diesel exhaust fluid) in the USA – AUS 32 (aqueous urea solution)

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6 Malfunctions

See Faults - Cause - Remedy table for engine problems and corrective measures. (For more information see: 6.1 Faults - Cause - Remedy, page 165.)

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

The following are available for error identification: – Warning lights in the device display – Diagnostics software (For more information see: 7.1.3 Diagnostic tools, page 172.)

6.1 Faults - Cause - Remedy Malfunction / error

Cause

Remedy

Starter does not crank.

Main fuse defective

Replace fuse.

Starter does not crank.

Battery connections loose or corroded

Clean and tighten loose connections.

Clean contacts.

Starter does not crank.

Battery voltage too low

Charge or replace battery.

Starter does not crank.

Starter circuit interrupted

Contact Liebherr customer service.

Starter does not crank.

Contacts corroded

Clean contacts.

Starter does not crank.

Starter defective

Contact Liebherr customer service.

Starter cranks slowly.

Battery voltage too low

Charge or replace battery.

Starter cranks slowly.

Battery connections loose or corroded

Clean and tighten loose connections.

Starter cranks slowly.

Outside temperature too low

Follow measures for winter operation.

Starter cranks slowly.

Engine under load

Disconnect the unit from the auxiliary output.

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

Engine stops immediately after starting.

Fuel tank empty

Engine stops immediately after starting.

Fuel fine filter clogged

D936 A7-04 / D946 A7-04 / LWE / 2019040001

Refuel.

Ventilate the fuel system.

Replace the fuel fine filter.

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Faults - Cause - Remedy

Malfunction / error

Cause

Remedy

Engine stops immediately after starting.

Fuel prefilter clogged

Replace the fuel prefilter.

Engine stops immediately after starting.

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

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

Ventilate the fuel system.

Engine stops immediately after starting.

Fuel not cold-resistant

Clean the fuel prefilter.

Replace the fuel fine filter.

Use winter fuel.

Engine stops immediately after starting.

Outside temperature too low

Follow measures for winter operation.

Engine stops immediately after starting.

Heating flange defective (at cold temperatures)

Check heating flange, replace if necessary.

Engine stops immediately after starting.

Exhaust gas system dirty

Clean exhaust gas system.

Engine stops immediately after starting.

Engine brake flap closed

Check engine brake flap control.

Engine starts poorly.

Leak or too low pressure in the fuel low pressure circuit

Contact Liebherr customer service.

Perform leak test (visual inspection).

Contact Liebherr customer service.

Engine starts poorly.

Engine compression too low

Contact Liebherr customer service.

Engine starts poorly.

Heating flange defective (at cold temperatures)

Check heating flange, replace if necessary.

Engine starts poorly.

Fault of the electronics

Contact Liebherr customer service.

Engine starts poorly.

Rail pressure too low

Inspect rail for leaks.

Engine starts poorly.

Air in fuel system

Ventilate the fuel system.

Engine starts poorly.

Air filter clogged

Check air filter for contamination.

Engine starts poorly.

Inferior fuel quality

Only use fuel recommended by Liebherr.

Engine starts poorly.

Injector defective

Contact Liebherr customer service.

Engine starts poorly.

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

For engines without hydraulic tappets: Check valve clearance.

If necessary, set valve clearance.

For engines with hydraulic tappets: Contact Liebherr customer service.

Engine turns off inadvertently.

Voltage supply interrupted

Contact Liebherr customer service.

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Operator's manual

Malfunctions Faults - Cause - Remedy

Malfunction / error

Cause

Engine turns off inadvertently.

Leak or too low pressure in the fuel low pressure circuit

Remedy Perform leak test (visual inspection).

Have checked by Liebherr customer service.

Engine turns off inadvertently.

Fault of the electronics

Contact Liebherr customer service.

Engine turns off inadvertently.

Fuel supply not ensured

Check fuel system.

Power reduction of the engine

Fuel system defective

Perform visual inspection.

Replace filter.

Power reduction of the engine

Charging pressure too low

Check clamps, seals, hoses and air filter.

Power reduction of the engine

Charge air temperature too high

Check charge air cooler, fan and ambient temperature.

Power reduction of the engine

Coolant temperature too high

Check cooler for contamination.

Check fan.

Check thermostat.

Check coolant level.

Power reduction of the engine

Fuel temperature too high

Contact Liebherr customer service.

Power reduction of the engine

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

Power reduction of the engine

Injectors stick or do not spray.

Contact Liebherr customer service.

Power reduction of the engine

Engine compression too low

Contact Liebherr customer service.

Power reduction of the engine

Fault of the electronics

Read error memory of the engine control unit.

Power reduction of the engine

Exhaust aftertreatment system clogged

Contact Liebherr customer service.

Power reduction of the engine

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

For engines without hydraulic tappets: Check valve clearance.

If necessary, set valve clearance.

For engines with hydraulic tappets: Contact Liebherr customer service.

Power reduction of the engine

Too little reducing agent in reducing agent tank

Fill up reducing agent.

Insufficient engine brake power

Engine brake flap without function

Check engine brake flap for function and damage.

No defect, engine power automatically reduced.

Contact Liebherr customer service.

Insufficient engine brake power

D936 A7-04 / D946 A7-04 / LWE / 2019040001

Fault of the electronics

Contact Liebherr customer service.

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Malfunctions

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Faults - Cause - Remedy

Malfunction / error

Cause

Remedy

Hot engine (according to coolant temperature display).

Too little coolant

Refill.

Hot engine (according to coolant temperature display).

Cooler dirty inside or calcified, cooler dirty outside

Clean cooler.

Hot engine (according to coolant temperature display).

Thermostat defective

Check thermostat.

Hot engine (according to coolant temperature display).

Coolant temperature sensor defective

Decalcify cooler.

If necessary, replace thermostat.

Check coolant temperature sensor.

If necessary, replace coolant temperature sensor.

Hot engine (according to coolant temperature display).

Fan speed too low (only hydrostatic fan drive)

Check fan drive.

Hot engine (according to coolant temperature display).

Coolant pump defective

Replace coolant pump.

Hot engine (according to coolant temperature display).

V-ribbed belt tension insufficient

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

Charging current indicator light illuminates when engine is running.

V-ribbed belt torn

Replace V-ribbed belt.

Charging current indicator light illuminates when engine is running.

Cable connections loose or disconnected

Fasten or replace cable.

Charging current indicator light illuminates when engine is running.

Alternator, rectifier or controller defective

Contact Liebherr customer service.

Charging current indicator light illuminates when engine is running.

Open test circuit

Contact Liebherr customer service.

Engine smokes black.

Exhaust aftertreatment system defective

Contact Liebherr customer service.

Engine smokes black.

Injection system defective

Contact Liebherr customer service.

Engine smokes black.

Charge air pressure sensor defective

Replace charge air pressure sensor.

Exhaust gases are blue.

Oil level in engine too high

Correct oil level.

Exhaust gases are blue.

Engine oil burns in combustion chambers.

Contact Liebherr customer service.

Exhaust gases are blue.

Compressor-side seal on the exhaust gas turbocharger defective

Contact Liebherr customer service.

Exhaust gases are blue.

Exhaust gas-side seal on the exhaust gas turbocharger defective

Contact Liebherr customer service.

Exhaust gases are blue.

Crankcase breather system defective

Check, replace if necessary.

Exhaust gases are blue.

Piston rings defective

Contact Liebherr customer service.

Exhaust gases are blue.

Valve stem seals defective

Contact Liebherr customer service.

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If necessary, replace fan drive.

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Operator's manual

Malfunctions Faults - Cause - Remedy

Malfunction / error

Cause

Remedy

Exhaust gases are white.

Injection delayed

Contact Liebherr customer service.

Exhaust gases are white.

Heating flange defective (temperature < -10 °C)

Check heating flange. If necessary, replace heating flange.

Exhaust gases are white.

Coolant in combustion chamber

Contact Liebherr customer service.

Engine rattles.

Combustion faults

Contact Liebherr customer service.

Engine knocks.

Injection nozzles damaged or coked

Contact Liebherr customer service.

Engine knocks.

Bearing damage

Contact Liebherr customer service.

Engine knocks.

Piston rings worn, piston rings broken, piston scuffed

Contact Liebherr customer service.

Abnormal noises

Leaks on suction lines and exhaust pipes cause whistling noises.

Eliminate leak. If necessary, replace seal.

Abnormal noises

Foreign object in compressor or turbine

Contact Liebherr customer service.

Abnormal noises

Turbine wheel or compressor wheel rubbing against housing

Contact Liebherr customer service.

Abnormal noises

Seized bearings on rotating parts

Contact Liebherr customer service.

Lubricating oil pressure too low

Oil level in the oil pan too low

Correct oil level.

Lubricating oil pressure too low

Engine oil too thin

Drain oil.

Fill the oil.

Determine cause of the oil dilution and rectify.

Lubricating oil pressure too low

Oil pressure sensor defective

Check engine oil system.

Replace damaged oil pressure sensor.

Lubricating oil pressure too low

End control valve defective

Contact Liebherr customer service.

Lubricating oil pressure too low

End control valve dirty

Contact Liebherr customer service.

Lubricating oil pressure too low

Bearing play due to wear too great or bearing damage

Contact Liebherr customer service.

Lubricating oil pressure too low

Oil pump defective

Check oil pump.

Replace oil pump, if necessary.

Lubricating oil pressure too low

Oil filter clogged

Replace oil filter.

Lubricating oil pressure too low

Oil pressure regulating valve defective

Contact Liebherr customer service.

Engine oil in cooling system

Oil cooler or oil cooler plate is leaking

Contact Liebherr customer service.

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Malfunctions

Operator's manual

Faults - Cause - Remedy

Malfunction / error

Cause

Coolant in engine oil

O-rings on cylinder liners are leaking

Contact Liebherr customer service.

Coolant in engine oil

Oil cooler or oil cooler plate is leaking

Contact Liebherr customer service.

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Remedy

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7 Tools and devices

7.1 Tools 7.1.1 Special tool Graphic representation

D936 A7-04 / D946 A7-04 / LWE / 2019040001

Description

Required number

Identification number

Turning device

1

0524045

Turning device

1

10134822

Turning device

1

10138480

Turning device

1

10118801

Turning device

1

10116805

Drain hose

1

12690422

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Tools and devices

Operator's manual

Tools

Graphic representation

Description

Required number

Identification number

Drain hose 90°

1

12690423

Tab. 41: Special tool

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

Locking agent Designation Identification number Quantity Loctite 243

811205708

50 ml

Tab. 42: Locking agent Sealant Designation Identification number Quantity Loctite 5910 10354595

300 ml

Tab. 43: Sealant Lubricants Designation

Identification number Quantity

NBU 30 grease 10285708

1 kg

Motorex 14

10002552

850 g

Altemp QNB 50 10490569

80 g

Tab. 44: Lubricants

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

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Operator's manual

Tools and devices Devices

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

Will lead to death or serious injuries due to crushing.

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

Observe maximum weight for lifting points.

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

Use a Liebherr lifting traverse. ( external link to 2001265 [heading], 1) (For more information see: 7.2.1 Lifting traverse with three-point-raising (basic version), page 173.)

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

Observe national and international guidelines for lifting heavy loads.

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

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

max.10°

4 1

4 5

3

4

5

3

3

5

1

1 1

2

B

2

2

D

C

A max.6° max.6° 5

2 E

F

Fig. 176: Lifting the engine A

Transport device detail view

1

Tolerance for maximum deviation of motor axis

See next page for continuation of the image legend

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Tools and devices

Operator's manual

Devices

B

2

Crankcase

C D

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

3 4

E

Lifting traverse lifting point detail view

5

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

F

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

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

Fig. 177: Lifting traverse basic version (10815480) 1 2 3

Chain suspension T-slide piece Attachment point sticker(see: fig. 178, page 175)

4 5

I-reception tube I-slide piece

Note When ordering ID no. 10815480, all parts, pos. 1 to 5, are delivered.

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Operator's manual

Tools and devices Devices

Fig. 178: Attachment point sticker

7.2.2 Lifting traverse with two-point-raising

Fig. 179: Lifting traverse with two-point-raising 1 2

I-slide piece I-reception tube

D936 A7-04 / D946 A7-04 / LWE / 2019040001

3

Chain suspension

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Tools and devices

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Devices

7.2.3 Engine assembly stand

Fig. 180: Engine assembly stand 1 2 3

Universal mount Engine assembly stand Height

4 5

Length Width

Engine assembly stand

10471324

12696052

Load bearing capacity

2500 kg

2500 kg

Drive

mechanical

electric

mobile

Yes

Yes

Oil drip pan

Yes

Yes

Height adjustment with compressed air

Yes, 350 mm

No

Dimensions Width Length Height

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

Own weight

approx. 1250 kg

Universal mount

10467810 2500 kg

approx. 1100 kg

Tab. 45: Technical data

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Operator's manual

Tools and devices Devices

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

Will lead to death or serious injuries due to crushing.

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

Observe maximum weight for lifting points.

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

Use a Liebherr lifting traverse. ( external link to 2001265 [heading], 1) (For more information see: 7.2.1 Lifting traverse with three-point-raising (basic version), page 173.)

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

Observe national and international guidelines for lifting heavy loads.

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

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

Tightening instruction for M10x30 10.9 FLZN hex bolt Lubricant

-

Locking agent

Loctite 243

Part contact surfaces

-

Screws

Reusable

Stage

Tightening torque

1.

Standard torque

Tightening sequence

Tab. 46: Tightening instruction Tightening instruction for M16x50 8.8 FLZN hex bolt Lubricant

-

Locking agent

-

Part contact surfaces

-

Screws

Reusable

Stage

Tightening torque

1.

Standard torque

Tightening sequence

Tab. 47: Tightening instruction

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Tools and devices

Operator's manual

Devices

Tightening instruction for M16x35 10.9 FLZN hex bolt Lubricant

-

Locking agent

-

Part contact surfaces

-

Screws

Reusable

Stage

Tightening torque

1.

Standard torque

Tab. 48: Tightening instruction

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8 Appendix

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

ISO 4014 ISO 4017 ISO 8765 ISO 8676

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

Values for an average coefficient of friction of

= 0.12

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

Nm

Strength class

ft/lb

Nm

8.8

ft/lb

Nm

10.9

ft/lb 12.9

M4

3

2

4

3

5

4

M5

6

4

8

6

10

7

M6

10

7

14

10

17

13

M7

16

12

23

17

27

20

M8

23

17

34

25

40

30

M10

46

34

68

50

79

58

M12

79

58

117

86

135

100

M14

125

92

185

136

215

159

M16

195

144

280

207

330

243

M18

280

207

390

288

460

339

M20

390

288

560

413

650

479

M22

530

391

750

553

880

649

M24

670

494

960

708

1120

826

M27

1000

738

1400

1033

1650

1217

M30

1350

996

1900

1401

2250

1660

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Appendix

Operator's manual

Tightening torques

Standard thread

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

M33

1850

1364

2600

1918

3000

2213

M36

2350

1733

3300

2434

3900

2876

M39

3000

2213

4300

3172

5100

3762

ft/lb

Nm

ft/lb

Tab. 49: Tightening torques for metric standard thread Standard thread

Nm

Strength class

ft/lb

Nm

8.8

10.9

12.9

M8x1

25

18

36

27

43

32

M9x1

36

27

53

39

62

46

M 10 x 1

52

38

76

56

89

66

M 10 x 1.25

49

36

72

53

84

62

M 12 x 1.25

87

64

125

92

150

111

M 12 x 1.5

83

61

122

90

145

107

M 14 x 1.5

135

100

200

148

235

173

M 16 x 1.5

205

151

300

221

360

266

M 18 x 1.5

310

229

440

325

520

384

M 18 x 2

290

214

420

310

490

361

M 20 x 1.5

430

317

620

457

720

531

M 22 x 1.5

580

428

820

605

960

708

M 24 x 1.5

760

561

1090

804

1270

937

M 24 x 2

730

538

1040

767

1220

900

M 27 x 1.5

1110

819

1580

1165

1850

1364

M 27 x 2

1070

789

1500

1106

1800

1328

M 30 x 1.5

1540

1136

2190

1615

2560

1888

M 30 x 2

1490

1099

2120

1564

2480

1829

M 33 x 1.5

2050

1512

2920

2154

3420

2522

M 33 x 2

2000

1475

2800

2065

3300

2434

M 36 x 1.5

2680

1977

3820

2817

4470

3297

M 36 x 3

2500

1844

3500

2581

4100

3024

M 39 x 1.5

3430

2530

4890

3607

5720

4219

M 39 x 3

3200

2360

4600

3393

5300

3909

Tab. 50: Tightening torques for metric fine thread For hex bolts according to: – DIN 6921 – DIN EN 1665 For cylinder screws according to: DIN EN ISO 4762 (formerly DIN 912) Values for an average coefficient of friction of

= 0.12

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Operator's manual

Appendix Tightening torques

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

Nm

Nm

Strength class

8.8

10.9

M4

2.2

3.3

M5

4.5

7

M6

8

12

M7

13

19

M8

19

28

M10

38

55

M12

65

95

M14

104

150

M16

158

234

M18

230

326

M20

320

450

Tab. 51: Tightening torques for metric standard thread Standard thread

Nm

Nm

Strength class

8.8

10.9

M8x1

20

29

M9x1

29

42

M 10 x 1

40

59

M 10 x 1.25

39

57

M 12 x 1.25

69

102

M 12 x 1.5

67

99

M 14 x 1.5

109

160

M 16 x 1.5

165

240

M 18 x 1.5

245

350

M 18 x 2

238

335

M 20 x 1.5

340

480

Tab. 52: Tightening torques for metric fine thread

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

Locking screws according to DIN 910.

Locking screws according to DIN 908.

With copper seal according to DIN 7603:

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Appendix

Operator's manual

Tightening torques

Standard thread

Nm

ft/lb

Standard thread

Nm

ft/lb

M6x1

7

5

M 20 x 1.5

47

35

M8x1

7.5

6

M 22 x 1.5

57

42

M 8 x 1.5

7.5

6

M 24 x 1.5

68

50

M 10 x 1

15

11

M 26 x 1.5

75

55

M 10 x 1.25

15

11

M 27 x 2

87

64

M 12 x 1.5

20

15

M 30 x 1.5

115

85

M 14 x 1.5

27

20

M 30 x 2

115

85

M 16 x 1.5

37

27

M 33 x 2

120

89

M 18 x 1.5

40

30

M 36 x 1.5

155

114

M 36 x 2

155

114

M 52 x 1.5

380

280

M 38 x 1.5

171

126

M 52 x 2

380

280

M 39 x 2

215

159

M 56 x 2

430

317

M 42 x 1.5

240

177

M 60 x 2

510

376

M 42 x 2

240

177

M 64 x 2

570

420

M 45 x 1.5

270

199

M 65 x 2

620

457

M 45 x 2

270

199

M 48 x 1.5

300

221

M 48 x 2

300

221

Tab. 53: Tightening torques for locking screws and banjo bolts

8.1.3 Standard torques for metric flange connections

Fig. 184: Overview of flange connections

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Appendix Tightening torques

Note Tightening torques apply for mating material: Steel.

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

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

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

Thread Y

Form A with sealing ring

Form B with sealing edge

6

Form E with flat (ED) seal

Form F with oring

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

M 10 x 1.0

9

7

18

13

18

13

15

11

8

M 12 x 1.5

20

15

30

22

25

18

25

18

10

M 14 x 1.5

35

26

45

33

45

33

35

26

12

M 16 x 1.5

45

33

65

48

55

41

40

30

15

M 18 x 1.5

55

41

80

59

70

52

45

33

18

M 22 x 1.5

65

48

140

103

125

92

60

44

22

M 26 x 1.5

90

66

190

140

180

133

100

74

28

M 33 x 2.0

150

111

340

251

310

229

160

118

35

M 42 x 2.0

240

177

500

369

450

332

210

155

42

M 48 x 2.0

290

214

630

465

540

398

260

192

Tab. 54: Metric screw connection series L (light), part 1 Pipe diameter X

Thread Y

WH

TH

SWVE

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

6

M 10 x 1.0

18

13

18

13

18

13

8

M 12 x 1.5

45

33

45

33

35

26

10

M 14 x 1.5

55

41

55

41

50

37

12

M 16 x 1.5

80

59

80

59

60

44

15

M 18 x 1.5

100

74

100

74

80

59

18

M 22 x 1.5

140

103

140

103

120

89

22

M 26 x 1.5

320

236

320

236

130

96

28

M 33 x 2.0

360

266

360

266

35

M 42 x 2.0

540

398

540

398

42

M 48 x 2.0

700

516

700

516

Tab. 55: Metric screw connection series L (light), part 2

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Tightening torques

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

Thread Y

Form A with sealing ring

Form B with sealing edge

Form E with flat (ED) seal

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

6

M 12 x 1.5

20

15

35

26

40

30

8

M 14 x 1.5

35

26

55

41

40

30

10

M 16 x 1.5

45

33

70

52

70

52

12

M 18 x 1.5

55

41

110

81

90

66

14

M 20 x 1.5

55

41

150

111

125

92

16

M 22 x 1.5

65

48

170

125

135

100

20

M 27 x 2.0

90

66

270

199

180

133

25

M 33 x 2.0

150

111

410

302

310

229

30

M 42 x 2.0

240

177

540

398

450

332

38

M 48 x 2.0

290

214

700

516

540

398

Tab. 56: Metric screw connection series S (heavy), part 1 Pipe diameter X

Thread Y

WH

TH

SWVE

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

6

M 12 x 1.5

45

33

45

33

35

26

8

M 14 x 1.5

55

41

55

41

50

37

10

M 16 x 1.5

80

59

80

59

60

44

12

M 18 x 1.5

100

74

100

74

80

59

14

M 20 x 1.5

125

92

125

92

110

81

16

M 22 x 1.5

135

100

135

100

120

89

20

M 27 x 2.0

320

236

320

236

135

100

25

M 33 x 2.0

360

266

360

266

30

M 42 x 2.0

540

398

540

398

38

M 48 x 2.0

700

516

700

516

Tab. 57: Metric screw connection series S (heavy), part 2

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

Thread Y Form A with sealing ring

Form B with sealing edge

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

6

G 1/8A

9

7

18

13

18

13

8

G 1/4A

35

26

35

26

35

26

10

G 1/4A

35

26

35

26

35

26

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Form E with flat (ED) seal

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Appendix Tightening torques

Pipe diameter X

Thread Y Form A with sealing ring

Form B with sealing edge

Form E with flat (ED) seal

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

12

G 3/8A

45

33

70

52

70

52

15

G 1/2A

65

48

140

103

90

66

18

G 1/2A

65

48

100

74

90

66

22

G 3/4A

90

66

180

133

180

133

28

G 1A

150

111

330

243

310

229

35

G 1 1/4A

240

177

540

398

450

332

42

G 1 1/2A

290

214

630

465

540

398

Tab. 58: Inch screw connection series S (light) - part 1 Pipe diameter X

Thread Y

WH

TH

SWVE

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

6

G 1/8A

18

13

18

13

18

13

8

G 1/4A

45

33

45

33

40

30

10

G 1/4A

45

33

45

33

40

30

12

G 3/8A

70

52

70

52

65

48

15

G 1/2A

120

89

120

89

90

66

18

G 1/2A

120

89

120

89

90

66

22

G 3/4A

230

170

230

170

125

92

28

G 1A

320

236

320

236

35

G 1 1/4A

540

398

540

398

42

G 1 1/2A

700

516

700

516

Tab. 59: Inch screw connection series S (light) - part 2

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

Thread Y Form A with sealing ring

Form B with sealing edge

Form E with flat (ED) seal

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

6

G 1/4A

35

26

55

41

40

30

8

G 1/4A

35

26

55

41

40

30

10

G 3/8A

45

33

90

66

80

59

12

G 3/8A

45

33

90

66

80

59

14

G 1/2A

65

48

150

111

115

85

16

G 1/2A

65

48

130

96

115

85

20

G 3/4A

90

66

270

199

180

133

25

G 1A

150

111

340

251

310

229

30

G 1 1/4A

240

177

540

398

450

332

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Tightening torques

Pipe diameter X

38

Thread Y Form A with sealing ring

G 1 1/2A

Form B with sealing edge

Form E with flat (ED) seal

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

290

214

700

516

540

398

Tab. 60: Inch screw connection series S (heavy) - part 1 Pipe diameter X

Thread Y

WH

TH

SWVE

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

6

G 1/4A

45

33

45

33

40

30

8

G 1/4A

45

33

45

33

40

30

10

G 3/8A

70

52

70

52

65

48

12

G 3/8A

70

52

70

52

65

48

14

G 1/2A

120

89

120

89

90

66

16

G 1/2A

120

89

120

89

90

66

20

G 3/4A

230

170

230

170

125

92

25

G 1A

320

236

320

236

30

G 1 1/4A

540

398

540

398

38

G 1 1/2A

700

516

700

516

Tab. 61: Inch screw connection series S (heavy) - part 2

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

Form A with sealing ring Nm

ft/lb

15

Form B with sealing edge Nm

Form E with flat (ED) seal

ft/lb

Nm

ft/lb

11

12

9

30

22

40

30

6

M 10 x 1.0

8

M 12 x 1.5

10

M 14 x 1.5

30

22

12

M 16 x 1.5

40

30

15

M 18 x 1.5

18

M 22 x 1.5

80

59

80

59

22

M 26 x 1.5

80

59

150

111

28

M 33 x 2.0

35

M 42 x 2.0

42

M 48 x 2.0

40

30

Tab. 62: Metric thread unit series L (up to 500 bar/7252 Psi) for aluminum Standard torques for cutting ring screw connections

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Appendix Tightening torques

Fig. 185: Cutting ring flange connections

Series

Pipe diameter X

Standard thread Z

LL

6

M 10 × 1

14

10

L

6

M 12 × 1.5

14

10

8

M 14 × 1.5

20

15

10

M 16 × 1.5

27–30

20 - 22

12

M 18 × 1.5

60

44

15

M 22 × 1.5

105

77

18

M 26 × 1.5

150

111

22

M 30 × 2

200

148

28

M 36 × 2

250

184

35

M 45 × 2

450

332

42

M 52 × 2

600

443

16

M 24 × 1.5

150

111

20

M 30 × 2

250

184

25

M 36 × 2

450

332

30

M 45 × 2

600

443

38

M 52 × 2

750

553

S

Nm

ft/lb

Tab. 63: Standard torques for cutting ring screw connections Note Tighten screw connections with the prescribed tightening torque.

Hold the screw connection in place.

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

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

Standard torques for Triple Lok® screw connections

Fig. 186: Triple lock flange connections

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Tightening torques

Series

Pipe diameter X mm

Standard thread Z

inch

Nm

UN/UNF

ft/lb Steel

Nm

ft/lb

Stainless steel

4

6

1/4

7/17-20

15

11

30

22

5

8

5/16

1/2-20

20

15

40

30

6

10

3/8

9/16-18

30

22

60

44

8

12

1/2

3/4-16

60

44

115

85

10

14, 15, 16

5/8

7/8-14

75

55

145

107

12

18, 20

3/4

1 1/16-12

110

81

180

133

16

22

7/8

1 5/16-12

135

100

225

166

25

1

1 5/16-12

175

129

255

188

1 5/8-12

260

192

295

218

1 5/8-12

260

192

295

218

1 7/8-12

340

251

345

254

1 7/8-12

340

251

345

254

2 1/4-12

380

280

400

295

2 1/2-12

450

332

470

347

28 20

30, 32

1 1/4

35 24

38

28

42

32

50

1 1/2

2

Tab. 64: Standard torques for Triple Lok® screw connections Note Screw tight the screw connections with the prescribed tightening torque.

Hold the screw connection in place.

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

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

Standard torques for VSTI screw plugs

Fig. 187: VSTI screw plugs

Standard thread

Nm

ft/lb

Standard thread

ft/lb

M 10 x 1

10

7

M 26 x 1.5

100

74

M 12 x 1.5

20

15

M 27 x 2

120

89

M 14 x 1.5

30

22

R 3/4”

120

89

M 16 x 1.5

40

30

M 30 x 1.5

120

89

M 18 x 1.5

50

37

M 33 x 2

200

148

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Appendix Tightening torques

Standard thread

Nm

ft/lb

Standard thread

Nm

ft/lb

M 20 x 1.5

60

44

M 38 x 1.5

280

207

M 22 x 1.5

80

59

M 42 x 2

350

258

M 24 x 1.5

90

66

M 48 x 2

400

295

Tab. 65: Standard torques for VSTI screw plugs

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Supplemental Information USA

8.2 Supplemental Information USA Additional information for the United States Environmental Protection Agency (mentioned in the following „EPA“) and the California Air Resources Board (mentioned in the following „CARB“).

8.2.1 Emission warranty Liebherr warrants to the initial and subsequent owners of an off-road equipment certified diesel engine that such engine is: – Designed, manufactured and equipped to conform at the time of sale with all applicable emission regulations adopted by (a) the state of California and the California Air Resources Board (“CARB”) and (b) the United States Environmental Protection Agency (“EPA”) under Section 213 of the Clean Air Act. – Free from defects in materials and workmanship with respect to the warranted emission control system and components for a period of five (5) years or 3000 hours of total operation by all persons, whichever event occurs first, after date of delivery to the initial owner.

If any warranted part that is scheduled for replacement as required maintenance fails prior to the first scheduled replacement point for that part, that part will be repaired or replaced by Liebherr. If a component of the emission control system fails during the warranty period, it will be repaired or replaced under warranty and warranted for the remainder of the warranty period. Liebherr will provide the repair or replacement of any component warranted to the off-road equipment engine owner. The warranty period begins on the date the engine (in service) or machine (in production) is delivered to the initial owner, and upon any sale of the engine by such initial owner to a subsequent owner, the warranty period does not restart, but rather the remaining balance of the warranty period transfers to the subsequent owner.

8.2.2 Warranted parts The following parts (as equipped) are warranted under this warranty for all Liebherr engines: – Fuel Injection System – Air Induction System – Turbocharger System – Charge Air Cooling System – Exhaust Gas Recirculation (EGR) System – EGR Control System – Exhaust Manifold – Ignition System – Diesel Particulate Filter System – Diesel Oxidation Catalyst – Fuel Additive Devices or Exhaust Aftertreatment Devices – Selective Catalyst Reduction – Reductant Containers – Electronic Control Unit, Sensors, Solenoids, and Wiring Harnesses – Emission Control Information Label – Crankcase Ventilation Valves

8.2.3 RESPONSIBILITIES & LIMITATIONS This warranty is subject to the following conditions.

Liebherr’s Responsibilities:

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In case an emission-related defect is found in a warranted component during the warranty period, Liebherr will provide: – New, remanufactured, or properly repaired components, approved pursuant to applicable regulations, required to correct the defect.

– Reasonable and customary labor as established by Liebherr, during normal working hours, required to make the warranted repairs, including labor to remove and install the engine, if so required. For machines or engines located in California during the warranty period, the failure of a warranted part will be repaired or replaced at no charge to the owner.

– Parts replaced under this warranty become the property of Liebherr.

Owner’s Responsibilities: During the warranty period, the owner of the off-road equipment engine is responsible for: – Premium or overtime labor costs (except for engines or equipment located in California).

– Costs to investigate engine problems which are not caused by a defect in Liebherr’s material or workmanship (except for engines or equipment located in California).

– Liebherr may deny warranty coverage if the heavy-duty off-road engine or a part thereof has failed due to abuse, neglect, improper maintenance, or unapproved modifications.

– Providing timely notice of a warranted failure to an authorized Liebherr Dealer, and to promptly make the equipment or engine available to the Liebherr Dealer for repair.

– Proper scheduled and preventive maintenance as outlined in the Operation & Maintenance Manual supplied with the equipment. This includes, but is not limited to, valve adjustment, fuel and oil filter changes, and any other maintenance procedure related to emission control.

– Using the proper fuel in the engine, as specified in the Operator’s Manual. Engines other than Tier 4 diesel engines shall only be operated on commercially available diesel fuel. Use of any other fuel may result in the engine no longer operating in compliance with EPA or California emission requirements. The Tier 4 diesel engine shall only be operated on ultra-low sulfur diesel fuel.

– The owner is responsible for initiating the warranty process. Owners are advised to contact their local authorized Liebherr Dealer to perform warranty service as soon as a problem arises. The warranty repairs should be completed by the authorized Liebherr Dealer as expeditiously as possible.

8.2.4 Exclusions This warranty does not cover: – This warranty shall only apply to Liebherr Machines Bulle SA engines.

– Malfunctions in any part caused by abuse, misuse, alterations, tampering, disconnection, or improper or inadequate maintenance.

– Attachments, accessories or components not supplied or approved by Liebherr.

– Damage resulting from fire, accident, negligence, act of God or other events beyond the control of Liebherr.

– Consequential damages such as loss of use of the engine or equipment powered by the engine, towing, machine transportation, loss of time, downtime, inconvenience, telephone, travel, lodging, or any other indirect or direct damages.

– Loss or damage to personal property, loss of revenue, commercial loss or any other matters not specifically included in this warranty statement.

– Any warranted part that was required to be previously replaced as part of required scheduled maintenance.

– Owner’s unreasonable delay in making the equipment available after being notified of a potential product problem.

This warranty is in addition to the Liebherr Standard Warranty and any extended warranty (if applicable) for the equipment and engine involved. Remedies under this warranty are limited to the provisions as specified in this warranty statement.

IN NO EVENT SHALL LIEBHERR, ITS COMPONENT SUPPLIERS NOR THE SELLING DEALER BE LIABLE FOR ANY DELAY, WORK STOPPAGE, LOSS OF USE OF EQUIPMENT, LOSS OF TIME, INCONVENIENCE, LOSS OF PROFITS, OR ANY INDIRECT, INCIDENTAL,

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Supplemental Information USA

SPECIAL, OR CONSEQUENTIAL DAMAGES RESULTING FROM OR ATTRIBUTABLE TO, DEFECTS IN LIEBHERR PRODUCTS OR SERVICE, WHETHER RESULTING FROM NEGLIGENCE (INCLUDING GROSS NEGLIGENCE) OR OTHER TORT WARRANTY, CONTRACT, INDEMNITY, BREACH OF THE PROMISE TO REPAIR OR REPLACE CONTAINED HEREIN, STRICT LIABILITY OR OTHERWISE. IN ADDITION, LIEBHERR, ITS COMPONENT SUPPLIERS AND THE SELLING DEALER SHALL NOT BE LIABLE IN TORT OR STRICT LIABILITY FOR ANY ECONOMIC LOSS RESULTING, IN WHOLE OR IN PART, FROM THE MANUFACTURE OR SUPPLY OF THE PRODUCT, PARTS, COMPONENTS AND/OR LABOR. NOTWITHSTANDING ANYTHING IN THIS WARRANTY TO THE CONTRARY, THE MAXIMUM LIABILITY, IF ANY, OF LIEBHERR, ITS COMPONENT SUPPLIERS AND THE SELLING DEALER FOR ALL DIRECT DAMAGES SHALL NOT EXCEED THE PRICE OF THE PARTICULAR DEFECTIVE PRODUCT, PART OR SERVICE, AS APPLICABLE. THE STANDARD WARRANTY, THE EMISSION CONTROL WARRANTIES, AND THE EXTENDED LIMITED MACHINE AND POWERTRAIN WARRANTIES, IF APPLICABLE, ARE THE ONLY WARRANTIES APPLICABLE TO LIEBHERR PRODUCTS AND COMPONENTS USED IN LIEBHERR PRODUCTS AND ARE EXPRESSLY IN LIEU OF ANY WARRANTIES OR CONDITIONS OTHERWISE IMPLIED BY LAW (INCLUDING ANY WARRANTY OTHERWISE IMPLIED BY LAW FOR THE PRODUCT BY THE MANUFACTURER OR ITS COMPONENT SUPPLIERS), INCLUDING, BUT NOT LIMITED TO, IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND IS NOT A WARRANTY OF FUTURE PERFORMANCE. THE REMEDIES UNDER THIS WARRANTY SHALL BE THE ONLY REMEDIES AVAILABLE TO THE OWNER OF LIEBHERR PRODUCTS OR ANY OTHER PERSON, AND NEITHER LIEBHERR NOR THE SELLING DEALER ASSUMES ANY OTHER OBLIGATION OR RESPONSIBILITY WITH RESPECT TO THE CONDITION OF LIEBHERR PRODUCTS, AND AUTHORIZES NO OTHER PERSON TO ASSUME FOR ANY OF THEM, ANY OTHER OBLIGATION OR LIABILITY. Liebherr reserves the right to make changes in design or add any improvements on its products at any time without incurring any obligation to install same on units previously delivered.

If the original owner sells the engine and machine, the remaining period of this warranty shall be transferred to the new owner.

“Liebherr” means both Liebherr USA Co., a company of Liebherr International AG, as well as the Liebherr company that manufactured the product.

Liebherr request that each owner of the engine and machine complete and provide the following requested information, sign in the space indicated, retain a completed and signed copy of this statement for the owner’s records, and return a completed and signed copy of this statement to Liebherr. Failure to complete, sign, or return this form will not affect any owner’s rights or Liebherr’s obligations under this warranty statement and will not result in denial of warranty coverage by Liebherr.

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Appendix Supplemental Information USA

MODEL:

PIN (Prod. Id. No.):

NAME OF DEALER

NAME OF OWNER

SIGNATURE OF AUTHORIZED REPRESENTATIVE OF DEALER

SIGNATURE OF AUTHORIZED REPRESENTATIVE OF OWNER

CITY / STATE / ZIP CODE OF DEALER

CITY / STATE / ZIP CODE OF OWNER

-

DATE MACHINE PLACED INTO SERVICE Fig. 188

8.2.5 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT (CALIFORNIA ONLY) YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board is pleased to explain the emission control system warranty on your 2018, 2019, and 2020 Model Year engines. In California, new heavy-duty offroad engines must be designed, built and equipped to meet the State’s stringent anti-smog standards. Liebherr must warrant the emission control system on your engine for the periods of time listed below, provided there has been no abuse, neglect or improper maintenance of your engine.

Your emission control system may include parts such as the fuel injection system and the air induction system. Also included may be hoses, belts, connectors and other emission-related assemblies.

Where a warrantable condition exists, Liebherr USA, Co (“Liebherr”) will repair your heavy-duty offroad engine at no cost to you, including diagnosis, parts and labor.

MANUFACTURER’S WARRANTY COVERAGE: The 2018, 2019, and 2020 Model Year heavy-duty off-road engine emission control systems are warranted for five (5) years or 3000 hours of total operation by all persons, whichever event occurs first, after date of delivery to the initial owner. If any emission-related part on your engine is defective, the part will be repaired or replaced by Liebherr.

WARRANTED PARTS The emission-related parts (as equipped) that are warranted under this warranty for all Liebherr engines may include the following: – Fuel Injection System – Air Induction System – Turbocharger System – Charge Air Cooling System

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Supplemental Information USA

– – – – – – – – – – – –

Exhaust Gas Recirculation (EGR) System EGR Control System Exhaust Manifold Ignition System Diesel Particulate Filter System Diesel Oxidation Catalyst Fuel Additive Devices or Exhaust Aftertreatment Devices Selective Catalyst Reduction Reductant Containers Electronic Control Unit, Sensors, Solenoids, and Wiring Harnesses Emission Control Information Label Crankcase Ventilation Valves

OWNER’S WARRANTY RESPONSIBILITIES: As the off-road engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. Liebherr recommends that you retain all receipts covering maintenance of your off-road engine, but Liebherr cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

As the off-road engine owner, you should however be aware that Liebherr may deny warranty coverage if your off-road engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

Your engine is designed to operate on the fuel specified in your owner’s manual. Use of any other fuel may result in your engine no longer operating in compliance with California’s emissions requirements.

You are responsible for initiating the warranty process. The California Air Resources Board suggests that you present your off-road engine to Liebherr’s dealer as soon as a problem exists.

The warranty repairs should be completed by the dealer as expeditiously as possible.

If you have any question regarding your warranty rights and responsibilities, you should contact Liebherr at 1-877-806-1588.

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D936 A7-04 / D946 A7-04 / LWE / 2019040001