Liebherr Diesel engine D944 A7-00 LWE Operator's manual - PDF DOWNLOAD

Operator's manual Diesel engine D944 A7-00 / LWE From serial number 2019030002

enus

Document ID Order number: Issued: Version: Author:

ORIGINAL OPERATOR'S MANUAL 13416554 27.04.2020 00 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 D944 A7-00 / LWE 2019030002

Change history

Version From serial number Changes included 00

2018 03 0001

Issue

Document newly created 4/27/2020

Change history

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Operator's manual

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D944 A7-00 / LWE / 2019030002

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.

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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.

Symbols

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Preface

Operator's manual

Changes, conditions, copyright:

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

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

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Contents

1

Product description

13

1.1

Technical description

13

1.1.1

Design

13

1.1.2

Engine type itemization

14

1.1.3

Company nameplate

15

1.1.4

Cylinder designation, direction of rotation

17

1.1.5

Engine control unit type plate

18

1.2

2

Technical data

19

1.2.1

Diesel engine

19

1.2.2

Valve clearance

19

1.2.3

Valve clearance, auxiliary braking system (ABS)

19

1.2.4

Coolant thermostat

19

Safety

21

2.1

Labeling of warnings

21

2.1.1

21

Additional labels

2.2

Target group

22

2.3

Intended use

22

2.4

Foreseeable misuse

22

2.5

General safety instructions

23

2.6

Preventing personal injuries

25

2.6.1

Bruises

25

2.6.2

Burns and scalds

25

2.6.3

Fires and explosions

25

2.6.4

Poisoning

25

2.6.5

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

26

2.6.6

Electrical energy

26

2.6.7

Danger due to noise

26

2.7

Personal protective equipment

26

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Contents

Operator's manual

2.8

2.9

3

5

27

2.8.1

Safety instructions

27

2.8.2

Operating areas

28

2.8.3

Maintenance areas

28

2.8.4

Securing and releasing the diesel engine against accidental start-up

29

2.8.5

Emergency stop

30

Signage

30

2.10 Preventing material damages

31

Transport and storage

33

3.1

Dimensions and weights

33

3.2

Lifting the engine

34

3.3

Transport

36

3.3.1

Transport attachment

36

3.3.2

Transport device

37

3.4

4

Operating areas and maintenance areas

Storage

39

3.4.1

Storage

39

3.4.2

Storage time

43

Operation

45

4.1

Preliminary work for the initial commissioning of the engine

45

4.2

Starting the engine

46

4.3

Turning off the engine

48

Maintenance

49

5.1

Maintenance schedule

49

5.2

Preliminary work

52

5.2.1

Bringing the engine into maintenance position

52

5.2.2

As needed

52

5.3

Diesel engine

53

5.3.1

Checking the V-ribbed belt for damage

53

5.3.2

Checking the V-ribbed belt for tension

53

5.3.3

Checking the belt drive

54

5.3.4

Replacing the belt drive

57

5.3.5

Checking the engine mount

60

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Operator's manual

Contents

5.4

5.5

5.6

5.7

5.8

5.9

5.3.6

Checking the intake system for leaks and damage

61

5.3.7

Checking the exhaust system

62

Engine oil system

64

5.4.1

Checking the engine oil system for leaks and damage

64

5.4.2

Checking the engine oil level

67

5.4.3

Changing the engine oil

68

5.4.4

Replacing the oil separator filter insert

74

Cylinder head

77

5.5.1

77

Checking and setting the valve clearance

Cooling system

92

5.6.1

Checking the cooling system and heating system for leaks and damage

92

5.6.2

Checking the coolant level

93

5.6.3

Checking the concentration of the antifreeze agent in the coolant

93

5.6.4

Replacing the coolant

94

Fuel system

97

5.7.1

Checking the fuel system for leaks and damage

97

5.7.2

Replacing the fuel prefilter

98

5.7.3

Reducing the pressure in the fuel system

98

5.7.4

Replacing the fuel fine filter

98

5.7.5

Ventilating the fuel system

101

Air filter

102

5.8.1

Checking the air filter low pressure indicator

102

5.8.2

Cleaning the air filter dust discharge valve

102

5.8.3

Replacing the dry air filter main element

102

5.8.4

Replacing the dry air filter safety element

102

Electrical system

103

5.9.1

Checking the batteries

103

5.9.2

Checking the cable connections

103

5.9.3

Checking the engine control unit bearings for damage

103

5.9.4

Checking sensors, actuators, cable holders and plugs

104

5.9.5

Checking the heating flange

106

5.9.6

Replacing the heating flange

110

5.10 Lubricants and operating fluids

112

5.10.1 Fill quantities

112

5.10.2 Engine oil

112

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Contents

Operator's manual

6

7

113

5.10.4 Fuel

114

Malfunctions

115

6.1

115

Faults - Cause - Remedy

Tools and devices

121

7.1

121

7.2

8

5.10.3 Coolant

Tools 7.1.1

Special tool

121

7.1.2

Operating material

121

7.1.3

Diagnostic tools

122

Devices

123

7.2.1

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

123

7.2.2

Lifting traverse with two-point-raising

125

7.2.3

Engine assembly stand

126

7.2.4

Transport device

127

Appendix

129

8.1

Tightening torques

129

8.1.1

For hex bolts / cylinder screws / external hex bolts

129

8.1.2

For locking screws and banjo bolts

131

8.1.3

Standard torques for metric flange connections

132

8.1.4

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

133

8.1.5

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

134

8.1.6

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

134

8.1.7

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

135

8.1.8

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

136

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1 Product description

1.1 Technical description 1.1.1 Design

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

Viscous damper Air conditioning compressor (optional) Tension pulley Coolant pump V-ribbed belt Suspension device Oil filter

8 9 10 11 12 13 14

Water cooler supply Compensation tank supply Exhaust manifold 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

Flywheel Suspension device Cylinder head cover Fuel fine filter Crankcase breather system Air intake pipe

7 8 9 10 11 12

Control unit Heating flange Alternator Fuel high pressure pump Oil pan Cable harness

1.1.2 Engine type itemization Engine type D 94 4 A7 -00 Description D

Engine type: D = diesel engine Family (l/cylinder): 94: 2 l/cylinder

94 4

Number of cylinders A7

Injection system: A7 = Common Rail System

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Operator's manual

Product description Technical description

Engine type D 94 4 A7 -00 Description Type: Standard -00 Emission standard: Without emission type approval Exhaust aftertreatment system: No exhaust aftertreatment system Tab. 1: Engine type itemization

1.1.3 Company nameplate

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

Manufacturer DataMatrix-Code US type approval information Engine power at rated speed Identification number Engine variant (Liebherr internal type) Engine type Capacity Engine serial number Date of manufacture

11 12 13 14 15 16 17 18 19

US performance category EU exemption Fuel minimum requirements 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. 4: Company nameplate on the crankcase and on the air intake pipe 1

Company nameplate on the crankcase

2

Company nameplate on the air intake pipe

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

2019 03 0001 Engine serial number 2019

Year of manufacture 03

Type series: 03 = D944 0001 Sequential production number

Tab. 2: Engine serial number

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Operator's manual

Product description Technical description

1.1.4 Cylinder designation, direction of rotation Cylinder designation, engine serial number and firing order

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

Engine serial number Firing order

3

Cylinder designation

Direction of rotation

1

2

3

4

Fig. 6: Cylinder designation and direction of rotation 1

Flywheel side

2

Ancillary support housing side

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

Viewed from the flywheel 1, the crankshaft turns counterclockwise.

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Product description

Operator's manual

Technical description

1.1.5 Engine control unit type plate

Fig. 7: Engine control unit type plate (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. 8: Type plate on engine control unit 1

Type plate on engine control unit

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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

4

Firing order

1–3–4–2

Hole

mm 130

Stroke

mm 150

Displacement

l 8.0

Compression ratio

17.5:1

Direction of rotation of the diesel engine

Viewed from the flywheel: counterclockwise

Power group

LG 0 to LG 2

Rated power

see company nameplate

Rated speed

see company nameplate

Emission limits

Without emission type approval

1.2.2 Valve clearance Description

Unit Value

Valve clearance, inlet, cold

mm 0.3

Valve clearance, outlet, cold

mm 0.4

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

1.2.4 Coolant thermostat Description

Unit Value

Start of opening

°C 82

Completely opened

°C 92

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Product description

Operator's manual

Technical data

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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. 3 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. 4

2.1.1 Additional labels Note Identifies useful information and tips.

Tab. 5

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Safety

Operator's manual

Foreseeable misuse

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

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

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

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

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

– Only use the diesel engine for its intended purpose.

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

• Servicing the diesel engine.

• Maintaining the diesel engine.

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. See “Target group” chapter.

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

– Before any assembly work, make sure that the personnel are familiar with the operating and maintenance manual.

– Only allow personnel undergoing training to work on the diesel engine under the constant supervision of an experienced person – Check that personnel are conscious of safety and the hazards involved in their work on the following conditions: • Observe accident prevention regulations.

• Observe generally accepted occupational health and safety regulations.

• Observe the operating and maintenance manual.

– Ensure that the personnel wear safe working clothes.

– Make sure that the following are not worn: • Rings • Wristwatches • Ties • Scarves • Open jackets • Loose clothing – Make sure that the following equipment is available for assembly and that it is clean, complete and undamaged: • Tool basic equipment • Necessary devices • Necessary special tools – Replace any damaged tools.

– Keep the workplace clean and tidy.

– Take precautions for any emergency that may occur.

– Keep fire extinguishers and first-aid boxes close by.

– Keep the emergency telephone numbers close by.

– Make sure that the workplace is well lit.

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Safety

Operator's manual

General safety instructions

– Only perform assembly work if the diesel engine has been secured.

– Ensure that the diesel engine is not started by unauthorized persons.

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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.

– If the engine is running: Make sure that no objects come in contact with moving parts. Objects can be thrown back.

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 – Smoking is prohibited in the direct vicinity of the diesel engine.

– Avoid any fires, sparks or open flames when handling fuels and flammable liquids.

– Start the Diesel engine in accordance with the regulations in the operating and maintenance manual and the assembly manual.

– Repair any leaks and replace damaged components. Fuel and oil that squirts out of leaks can lead to fires.

– Wear safety goggles and gloves when working on batteries.

– Remove any cleaning rags that are soaked with flammable liquids.

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

2.6.4 Poisoning – – – –

Only run the diesel engine in closed rooms if these are sufficiently ventilated.

Open doors and windows if a bigger supply of fresh air is needed.

Never ingest any operating materials.

Do not use drinking bottles for storage purposes.

Escaping liquids can penetrate the skin and cause blood poisoning.

– Do not open any pressurized lines or hoses.

– Do not disconnect any pressurized lines or hoses.

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

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Safety

Operator's manual

Personal protective equipment

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

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

– Check the pressure reduction with the diagnostics software.

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

– Do not open any pressurized fuel lines or hoses.

– Do not disconnect any pressurized fuel lines or hoses.

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

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

– Do not touch any live parts.

– Before work on the electrical system: Disconnect the electrical power supply.

2.6.7 Danger due to noise Permanent hearing impediments are possible at noise levels above 84dB(A). Sound level up to 110dB(A) possible!

– Keep all sound-absorbing guards on the equipment closed when the engine is running.

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

– Pay attention to the hearing protection measures in accordance with the diesel engine's operating manual.

The operators and unauthorized personnel may not enter the safety zones when the engine is ready for use or running. However, if a technician has to approach an unprotected engine for troubleshooting work he must wear hearing protection suitable for the noise level.

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 Wear protective work clothing in the immediate vicinity of the engine.

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Safety Operating areas and maintenance areas

Safety helmet – Protect against falling or flying objects and against bumping your head Wear a safety helmet in the immediate vicinity of the engine.

Safety shoes – Foot protection against falling objects and pinching of the foot in heavy parts; additionally, protection against slipping Wear safety shoes in the immediate vicinity of the engine.

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

– Wear safety gloves when 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 splinters and splatters from chemicals Wear safety goggles when handling operating fluids. (See manufacturer's specifications for the operating fluids and safety data sheet for the operating fluid.)

– Wear safety goggles during mechanical interventions, such as for example, using compressed air.

Hearing protection – Protection against noise Wear hearing protection around the diesel engine when it is running.

Gas detector – Protection against escaping gases Wear a gas detector when working on the engine.

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.

– Wear personal protective equipment.

– Let the engine cool down sufficiently.

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Safety

Operator's manual

Operating areas and maintenance areas

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. 21: 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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Safety Operating areas and maintenance areas

A

D

B

B

B

B

C

E

a

b

Fig. 22: 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. copyright © Liebherr Machines Bulle SA 2020

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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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Safety Preventing material damages

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 material damages – Replace sealing material (e.g. o-rings, seals, etc.).

– Check reusable removed parts for re-usability; see the relevant information in the Service Manual and repair instructions.

– Replace removed, not reusable parts.

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

– Replace self-locking screwed assemblies.

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

– Use lint-free cleaning rags.

– Do not touch electric contacts. The connection is affected by dirt or components may be destroyed by electrostatic discharges (ESD).

– Before cleaning the Diesel engine, cover or tape shut all openings into which water, steam or detergents must not penetrate due to safety or functional reasons.

– Remove the covers/seals after cleaning.

– Check the fuel lines, Diesel engine oil lines and hydraulic lines for the following defects: • Leaks • Loose connections • Chafe marks • Damage – Make sure the electrical power supply is firmly connected when starting.

– Make sure the engine is switched off before disconnecting the electrical power supply.

– Use suitable test leads for measurements at plug connections.

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

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Preventing material damages

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3 Transport and storage

3.1 Dimensions and weights

2

1

3

Fig. 28: Dimensions 1 2

Width Height

3

Length

Description

Unit Value

Length

mm 1221

Width

mm 823

Height

mm 1154

Engine weight without operating fluids

kg 870

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

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Lifting the engine

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

Leads to death or serious injuries.

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

Observe maximum weight for lifting points.

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

Use a Liebherr lifting traverse. (For more information see: 7.2.1 Lifting traverse with three-pointraising (basic version), page 123.)

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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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. 29: 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

3.3 Transport 3.3.1 Transport attachment

Fig. 30: 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. 31: Wood transport device Only transport the engine using the transport device.

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Transport

Steel transport device DANGER Instability during transport!

Leads to death or serious injuries.

Only use the original transport device.

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

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

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

Observe the center of gravity.

Bolt the engine securely to the transport device.

Fig. 32: 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. 6: VCI film cover VCI bag LxW ID no.

300x200

11170517

345x260

11170521

Tab. 7: 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. 8: 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. 9: 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.

Fill the oil. (For more information see: Filling the engine oil, page 73.)

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 93.)

Fill the coolant, see documentation from the device manufacturer.

Check coolant line connections..

Connect air intake, see documentation from the device manufacturer.

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

Connect fuel supply, see documentation from the device manufacturer.

Provide diesel fuel with the approved fuel specification.

Fill the diesel fuel.

Ventilate the fuel system. (For more information see: 5.7.5 Ventilating the fuel system, page 101.)

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

Check fuel fine filter connection.

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

Upload current software update to engine control unit. (For more information see: 1.1.5 Engine control unit type plate, page 18.)

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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 45.)

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 49.)

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 115.)

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 115.)

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 115.)

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. 10: 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.

53

1000 h

Check belt drive.

54

1000 h

Check the engine mount.

60

500 h

1000 h

Check the intake system.

61

500 h

1000 h 5000 h / every five years

Check exhaust system.

62

Replace belt drive.

57

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

64

Check engine oil level.

67

Replace engine oil and oil filter.

68

Replace oil separator filter insert.

74

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.

77 92

Check coolant level.

93

Check the concentration of the antifreeze agent.

93

Replace coolant.

94

10 h

Fuel system Check fuel system for leaks and damage.

97

1000 h

Replace fuel prefilter.

98

1000 h

98

10 h

Replace fuel fine filter.

Air filter Check the air filter low pressure indicator.

50 h

Clean the air filter dust discharge valve.

102

Replace the dry air filter main element.

102 102

102

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.

103

500 h

1000 h

Check cable connections.

103

103

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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 10000 h

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

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

104

Check heating flange, if present.

106

Replace heating flange, if present.

110

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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.

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Maintenance Diesel engine

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

Cover is removed (if present).

Engine is in maintenance position. (For more information see: 5.2.1 Bringing the engine into maintenance position, page 52.)

Fig. 33: 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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Diesel engine

Fig. 34: Tension pulley (self-tensioning) 1

Tension pulley (self-tensioning)

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

– Cover is removed (if present).

– Engine is in maintenance position. (For more information see: 5.2.1 Bringing the engine into maintenance position, page 52.)

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Maintenance Diesel engine

Checking the (optional) air conditioning compressor belt drive Removing the belt

Fig. 35: Removing the air conditioning compressor belt 1 2

V-ribbed belt Tension pulley (self-tensioning)

3

Internal square

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

Move tension pulley (self-tensioning) 2 counterclockwise to relieve the V-ribbed belt 1.

Remove V-ribbed belt 1.

Replace belt drive, see repair instruction.

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Maintenance

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Diesel engine

Checking the belt drive

Fig. 36: Checking the air conditioning compressor belt drive 1 2 3

Air conditioning compressor Tension pulley (self-tensioning) Deflection pulley

4 5 6

Alternator 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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Maintenance Diesel engine

Installing the belt

Fig. 37: Installing the air conditioning compressor belt 1 2

V-ribbed belt Tension pulley (self-tensioning)

3

Internal square

Install new V-ribbed belt 1.

Slowly turn back tension pulley (self-tensioning) 2.

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

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

– Cover is removed (if present).

– Engine is in maintenance position. (For more information see: 5.2.1 Bringing the engine into maintenance position, page 52.)

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Diesel engine

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

Fig. 38: 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.

Replacing the deflection pulleys and tension pulley (self-tensioning) Make sure that the following prerequisites are met: Cover is removed (if present).

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Maintenance Diesel engine

Fig. 39: Replacing the deflection pulleys and tension pulley (self-tensioning) 1 2

Deflection pulley Tension pulley (self-tensioning)

3 4

Hex bolt Hex bolt

Unscrew hex bolt 3.

Remove deflection pulley 1.

Unscrew hex bolt 4.

Remove tension pulley (self-tensioning) 2.

Install new tension pulley (self-tensioning) 2.

Tighten hex bolt 4.

Install new deflection pulley 1.

Tighten hex bolt 3.

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Diesel engine

Installing the V-ribbed belt

Fig. 40: Replacing 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.

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. 41: Checking the intake system 1 2 3

External hex bolt (4x) External hex bolt (4x) 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 the engine.

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

Replace damaged components, see repair instruction.

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5.3.7 Checking the exhaust system

Fig. 42: 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.

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If components are damaged: Do not start the engine.

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

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Engine oil system

5.4 Engine oil system 5.4.1 Checking the engine oil system for leaks and damage 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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Fig. 43: Components to be checked 1 2 3 4 5

Oil pan Locking part Cylinder head gasket Oil filter Cylinder head cover seal

6 7 8 9 10

Oil separator Cylinder head cover Oil supply line Oil return line Oil cooler

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Engine oil system

Fig. 44: Components to be checked 1 2

Oil level sensor Oil dipstick

3 4

Crankcase breather system oil line Oil filler cap

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.

Replace damaged components, see repair instruction.

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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. 45: Checking the engine oil level 1 2

Oil filler neck Oil filler cap

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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Engine oil system

Pull out the oil dipstick 3.

Fig. 46: 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 73.)

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

Draining the engine oil Graphic representation

Description

Required number

Identification number

Drain hose

1

12690422

Drain hose 90°

1

12690423

Tab. 11: Special tool

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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. 49: Draining the engine oil 1 2

Oil drain valve Protecting cap

3

Drain hose

Unscrew protecting cap 2 from the oil drain valve 1.

Place the end of the drain hose 4 in the collection container.

Connect drain hose 3 to the oil drain valve 1.

The oil drain valve 1 opens and the oil drains.

Remove drain hose 3.

Seal oil drain valve 1 with the protecting cap 2.

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Engine oil system

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.

Fig. 50: Removing the oil filter 1

Nozzle (2x)

2

Oil filter (2x)

Unscrew oil filter 2.

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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.

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. 51: Installing the oil filter 1

Nozzle (2x)

2

Oil filter (2x)

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

Screw on new oil filter 2.

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

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Filling the engine oil

Fig. 53: Filling the engine oil (example filling on cylinder head cover) 1 2

Oil filler neck Oil filler cap

3

Oil dipstick

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 67.)

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.

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Engine oil system

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.

Fig. 54: 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. 55: 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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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. 56: 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. 57: 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. 58: 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. 13: Special tool

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Maintenance Cylinder head

Fig. 60: 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. 14: Special tool

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Cylinder head

Fig. 62: 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. 15: Special tool

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Fig. 64: Installing the turning device on the crankshaft 1

Turning device

2

Crankshaft

Turning device 1 on crankshaft 2

Setting the cylinder to top dead center (TDC) 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. 16: Differences between ignition TDC and overlapping TDC

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Cylinder head

Fig. 65: Valve overlap

Fig. 66: TDC marks: Ignition TDC for cylinder 1 1

TDC marking on the flywheel and flywheel housing Turn crankshaft with the turning device counterclockwise. copyright © Liebherr Machines Bulle SA 2020

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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

3

4

2

overlap (overlapping TDC)

4

2

1

3

Tab. 17: Valves of the cylinder

Setting cylinder 1 to ignition TDC

Fig. 67: 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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Cylinder head

Cylinder 1 is in ignition TDC position.

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

Set cylinder 2 to 4 to ignition TDC. Turn crankshaft with the turning device counterclockwise.

Check if the rocker arms of a cylinder overlap.

Press the cylinder rocker arm on the valve bridges.

Cylinder is in overlapping TDC position.

Check which cylinder is at ignition TDC and can thus be set. (For more information see: Setting table, page 83.)

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 52.)

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

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Maintenance Cylinder head

Fig. 68: Check the valve clearance. Setting the valve clearance 1 2 3 4

Feeler gauge Valve bridge Lock nut Allen wrench

5 6 7

Adjusting screw 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. 18: Tensioning instruction Tighten the lock nut 3 according to the tensioning instruction.

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Cylinder head

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.

Removing the turning device from the flywheel housing

Fig. 70: Removing the turning device from the flywheel housing 1 2

Flywheel housing Turning device

3

External hex bolt (3x)

Unscrew external hex bolt 3.

Remove turning device 2 from flywheel housing 1.

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Removing the turning device from the belt pulley

Fig. 71: Removing the turning device from the belt pulley 1 2

Cylinder screw (6x) Turning device

3

Belt pulley

Unscrew cylinder screw 1.

Remove belt pulley 3 from turning device 2.

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Cylinder head

Removing the turning device from the crankshaft

Fig. 72: Removing the turning device from the crankshaft 1

Turning device

2

Crankshaft

Remove turning device 1 from crankshaft 2.

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Installing the locking part

Fig. 73: 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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Cylinder head

Installing the cylinder head cover

Fig. 74: 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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Tensioning instruction for M4 hex nut Lubricant

-

Locking agent

-

Part contact surfaces

-

Screws

-

Stage

Tightening torque

1.

1.8 Nm

Tab. 19: Tensioning instruction 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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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. 76: Components to be checked 1 2 3 4

Drain plug Water cooler supply Coolant pump Expansion tank return

5 6 7 8

Cylinder head gasket Expansion tank supply Oil cooler Water cooler return

Check components for leaks.

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Maintenance Cooling system

Check components for damage.

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

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

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

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

Replace damaged components, see repair instruction.

5.6.2 Checking the coolant level 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 93.)

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. 77, page 94).

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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. 77: 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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Graphic representation

Description

Required number

Identification number

Drain hose

1

12690422

Drain hose 90°

1

12690423

Tab. 20: 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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Cooling system

Fig. 80: Draining the coolant on the engine 1 2

Protecting cap Drain valve

3 4

Oil cooler Drain hose

Release the end cover on the device side compensation tank.

Excess pressure escapes from the cooling system.

Put a collection container under the drain valve 2.

Unscrew protecting cap 1.

Screw drain hose 4 onto drain valve 2.

Coolant runs out.

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 93.)

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 the engine. (For more information see: 4.3 Turning off the engine, page 48.)

Let the engine cool down.

Check coolant level. (For more information see: 5.6.2 Checking the coolant level, page 93.)

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. 81: Components 1 2 3 4

Fuel high pressure pump Fuel fine filter Fuel fine filter console Injection pipes

5 6 7

Fuel line Distributor block 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 the engine Replace defective components, see repair instruction.

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 101.)

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 122.)

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. 82: Replacing the fuel fine filter 1

Fuel fine filter

2

Fuel fine filter console

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 122.)

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

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

Clean the fuel fine filter console 2 and surrounding area.

Remove fuel fine filter 1.

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.

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Fuel system

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. 83: Replacing the fuel fine filter 1

Fuel fine filter

2

Fuel fine filter console

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

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. 21: Tightening instruction

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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 101.)

5.7.5 Ventilating the fuel system

3

1

2

4

5

6

Fig. 85: 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.

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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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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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. 86: 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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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.

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Fig. 87: Cable harness (example application) 1 2 3 4

Speed sensor -B711 Interface for splitter box temperature sensor (optional) -X720 Phase sensor -B713 Wastegate control valve -Y705

13 14

Heating flange back measurement -E703 Heating flange -E703

15 16

Alternator back measurement -F705.X Alternator -G700

See next page for continuation of the image legend

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5 6 7 8 9 10 11 12

Pressure sensor -B702 Terminating resistor -X724.S Engine brake flap actuator -M715 Volume control valve VCV -Y703 High pressure regulating valve PCV -Y707 Injectors -Y731/-Y732/-Y733/-Y734 Coolant temperature sensor -B708 Temperature sensor -B707

17 18 19 20 21 22 23 24

Pressure sensor -B703 Fuel temperature sensor -B709 Pressure sensor -B704 Oil pressure sensor -B701 Interface -X710.S Oil temperature and level sensor -B730 Starter motor-M700 Starter motor - battery line KL30

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 urea solution.

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

Replace defective components, see repair instruction.

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.

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Fig. 88: 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 108.)

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Electrical system

Checking the heating flange for sooting

Fig. 89: 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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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. 22: 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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Electrical system

5.9.6 Replacing the heating flange Removing the heating flange

Fig. 91: 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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Installing the heating flange

Fig. 92: 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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Lubricants and operating fluids

5.10 Lubricants and operating fluids 5.10.1 Fill quantities Name

Fill quantity

Engine oil

25 l (including 1.5 l per filter)

Coolant (engine) 15 l Reduction agent See documentation from the device manufacturer.

Tab. 23: Fill quantities for oil change (reference values)

5.10.2 Engine oil 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

Engines without emission type approval

to 15

100% (standard interval according to maintenance schedule)

to 500

50%

500 - 2000

25%

2000 - 5000

13%

Liebherr recommends the use of the following products

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

Lubricating oil specification

LH-00-ENG

Tab. 24: 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

Engines without emission type approval

to 15

50%

to 500

25%

500 - 2000

13%

2000 - 5000

6%

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

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

Avoid combining different products.

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

Anticorrosive antifreeze agent Liebherr recommendation Type

Name

PremixA) Liebherr Antifreeze OS Mix Tab. 26: 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. 27: 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. 28: Minimum requirements for the quality

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5.10.4 Fuel Minimum requirement for the quality Approved diesel fuels according to DIN EN For diesel engines without emission type 590 and ASTM D975 approval Maximum sulfur content in the fuel

5000 ppm

Lubricity at 60 °C (HFRR)

460 m

Minimum cetane number

45

Tab. 29: Minimum requirement for diesel fuels Specification LH-00-FUEL Tab. 30: Specification for diesel fuels

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6 Malfunctions

See Faults - Cause - Remedy table for engine problems and corrective measures. (For more information see: 6.1 Faults - Cause - Remedy, page 115.)

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 122.)

6.1 Faults - Cause - Remedy Malfunction / error

Cause

Remedy

Starter dreht nicht durch.

Hauptsicherung defekt

Sicherung ersetzen.

Starter dreht nicht durch.

Batterieanschlüsse lose oder korrodiert

Lose Anschlüsse reinigen und festziehen.

Kontakte reinigen.

Starter dreht nicht durch.

Batteriespannung zu niedrig

Batterie laden oder ersetzen.

Starter dreht nicht durch.

Starterstromkreis unterbrochen

Liebherr-Kundendienst kontaktieren.

Starter dreht nicht durch.

Kontakte korrodiert

Kontakte reinigen.

Starter dreht nicht durch.

Starter defekt

Liebherr-Kundendienst kontaktieren.

Starter dreht langsam durch.

Batteriespannung zu niedrig

Batterie laden oder ersetzen.

Starter dreht langsam durch.

Batterieanschlüsse lose oder korrodiert

Lose Anschlüsse reinigen und festziehen.

Starter dreht langsam durch.

Außentemperatur zu niedrig

Maßnahmen für Winterbetrieb beachten.

Starter dreht langsam durch.

Motor unter Last

Aggregate vom Nebenabtrieb trennen.

Sicherstellen, dass Kraftschluss zwischen Motor und Kraftübertragung getrennt ist.

Motor bleibt unmittelbar nach Start stehen.

Kraftstoffbehälter leer

Motor bleibt unmittelbar nach Start stehen.

Kraftstoff-Feinfilter verstopft

Auftanken.

Kraftstoffsystem entlüften.

Kraftstoff-Feinfilter ersetzen.

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Malfunction / error

Cause

Remedy

Motor bleibt unmittelbar nach Start stehen.

Kraftstoff-Vorfilter verstopft

Kraftstoff-Vorfilter ersetzen.

Motor bleibt unmittelbar nach Start stehen.

Kraftstoffleitung, Vorreiniger oder Sieb in Kraftstoffbehälter verstopft

Kraftstoffleitung, Vorreiniger oder Sieb in Kraftstoffbehälter reinigen.

Kraftstoffsystem entlüften.

Motor bleibt unmittelbar nach Start stehen.

Kraftstoff nicht kältefest

Kraftstoff-Vorfilter reinigen.

Kraftstoff-Feinfilter ersetzen.

Winterkraftstoff verwenden.

Motor bleibt unmittelbar nach Start stehen.

Außentemperatur zu niedrig

Maßnahmen für Winterbetrieb beachten.

Motor bleibt unmittelbar nach Start stehen.

Heizflansch defekt (bei kalten Temperaturen)

Heizflansch prüfen, wenn notwendig ersetzen.

Motor bleibt unmittelbar nach Start stehen.

Abgasstrang verschmutzt

Abgasstrang reinigen.

Motor bleibt unmittelbar nach Start stehen.

Motorbremsklappe geschlossen

Steuerung der Motorbremsklappe prüfen.

Liebherr-Kundendienst kontaktieren.

Motor startet schlecht.

Undichtheit oder zu geringer Druck im Kraftstoff-Niederdruck-Kreislauf

Dichtheitsprüfung (Sichtprüfung) durchführen.

Liebherr-Kundendienst kontaktieren.

Motor startet schlecht.

Motorkompression zu gering

Liebherr-Kundendienst kontaktieren.

Motor startet schlecht.

Heizflansch defekt (bei kalten Temperaturen)

Heizflansch prüfen, wenn notwendig ersetzen.

Motor startet schlecht.

Störung der Elektronik

Liebherr-Kundendienst kontaktieren.

Motor startet schlecht.

Raildruck zu niedrig

Rail auf Undichtheiten untersuchen.

Motor startet schlecht.

Luft in Kraftstoffsystem

Kraftstoffsystem entlüften.

Motor startet schlecht.

Luftfilter verstopft

Luftfilter auf Verschmutzung prüfen.

Motor startet schlecht.

Minderwertige Kraftstoffqualität

Ausschließlich von Liebherr empfohlenen Kraftstoff verwenden.

Motor startet schlecht.

Injektor defekt

Liebherr-Kundendienst kontaktieren.

Motor startet schlecht.

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.

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Malfunction / error

Cause

Remedy

Motor stellt ungewollt ab.

Spannungsversorgung unterbrochen

Liebherr-Kundendienst kontaktieren.

Motor stellt ungewollt ab.

Undichtheit oder zu geringer Druck im Kraftstoff-Niederdruck-Kreislauf

Dichtheitsprüfung (Sichtprüfung) durchführen.

Von Liebherr-Kundendienst prüfen lassen.

Motor stellt ungewollt ab.

Störung der Elektronik

Liebherr-Kundendienst kontaktieren.

Motor stellt ungewollt ab.

Kraftstoffzufuhr nicht gewährleistet

Kraftstoffsystem prüfen.

Leistungsreduktion des Motors

Kraftstoffsystem defekt

Sichtprüfung durchführen.

Filter ersetzen.

Leistungsreduktion des Motors

Ladedruck zu gering

Schellen, Dichtungen, Schläuche und Luftfilter prüfen.

Leistungsreduktion des Motors

Ladelufttemperatur zu hoch

Ladeluftkühler, Lüfter und Umgebungstemperatur prüfen.

Leistungsreduktion des Motors

Kühlmitteltemperatur zu hoch

Kühler auf Verschmutzung prüfen.

Lüfter prüfen.

Thermostat prüfen.

Kühlmittelstand prüfen.

Leistungsreduktion des Motors

Kraftstofftemperatur zu hoch

Liebherr-Kundendienst kontaktieren.

Leistungsreduktion des Motors

Sauerstoffgehalt der Luft zu niedrig da Einsatzgebiet > 1800 m über Meeresspiegel

Leistungsreduktion des Motors

Injektoren bleiben hängen oder zerstäuben nicht.

Liebherr-Kundendienst kontaktieren.

Leistungsreduktion des Motors

Motorkompression zu gering

Liebherr-Kundendienst kontaktieren.

Leistungsreduktion des Motors

Störung der Elektronik

Fehlerspeicher vom Motorsteuergerät auslesen.

Leistungsreduktion des Motors

Abgasnachbehandlungssystem verstopft

Liebherr-Kundendienst kontaktieren.

Leistungsreduktion des Motors

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.

Leistungsreduktion des Motors

Zu wenig Reduktionsmittel in Reduktionsmittel-Tank

Reduktionsmittel auffüllen.

Ungenügende Motorbremsleistung

Motorbremsklappe ohne Funktion

Motorbremsklappe auf Funktion und Schäden prüfen.

Kein Defekt, Motorleistung automatisch reduziert.

Liebherr-Kundendienst kontaktieren.

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Malfunction / error

Cause

Remedy

Ungenügende Motorbremsleistung

Störung der Elektronik

Liebherr-Kundendienst kontaktieren.

Heißer Motor (nach Anzeige Kühlmitteltemperatur).

Zu wenig Kühlmittel

Nachfüllen.

Heißer Motor (nach Anzeige Kühlmitteltemperatur).

Kühler innen verschmutzt oder verkalkt, Kühler außen verschmutzt

Kühler reinigen.

Heißer Motor (nach Anzeige Kühlmitteltemperatur).

Thermostat defekt

Thermostat prüfen.

Heißer Motor (nach Anzeige Kühlmitteltemperatur).

Kühlmitteltemperatur-Geber defekt

Kühler entkalken.

Bei Bedarf Thermostat ersetzen.

Kühlmitteltemperatur-Geber prüfen.

Bei Bedarf KühlmitteltemperaturGeber ersetzen.

Heißer Motor (nach Anzeige Kühlmitteltemperatur).

Lüfter zu geringe Drehzahl (ausschließlich hydrostatischer Lüfterantrieb)

Lüfterantrieb prüfen.

Heißer Motor (nach Anzeige Kühlmitteltemperatur).

Kühlmittelpumpe defekt

Kühlmittelpumpe ersetzen.

Heißer Motor (nach Anzeige Kühlmitteltemperatur).

Spannung Keilrippenreimen unzureichend

Spannung Keilrippenreimen prüfen. Bei Bedarf Spannrolle ersetzen.

Kontrollleuchte Ladestrom leuchtet bei laufendem Motor.

Keilrippenriemen gerissen

Keilrippenriemen ersetzen.

Kontrollleuchte Ladestrom leuchtet bei laufendem Motor.

Kabelverbindungen lose oder getrennt

Kabel befestigen oder ersetzen.

Kontrollleuchte Ladestrom leuchtet bei laufendem Motor.

Generator, Gleichrichter oder Regler defekt

Liebherr-Kundendienst kontaktieren.

Kontrollleuchte Ladestrom leuchtet bei laufendem Motor.

Prüfkreis offen

Liebherr-Kundendienst kontaktieren.

Motor raucht schwarz.

Abgasnachbehandlungssystem defekt

Liebherr-Kundendienst kontaktieren.

Motor raucht schwarz.

Einspritzanlage defekt

Liebherr-Kundendienst kontaktieren.

Motor raucht schwarz.

Ladeluftdruck-Sensor defekt

Ladeluftdruck-Sensor ersetzen.

Abgase sind blau.

Ölstand in Motor zu hoch

Ölstand korrigieren.

Abgase sind blau.

Motoröl verbrennt in Brennräumen.

Liebherr-Kundendienst kontaktieren.

Abgase sind blau.

Verdichterseitige Abdichtung am Abgasturbolader defekt

Liebherr-Kundendienst kontaktieren.

Abgase sind blau.

Abgasseitige Abdichtung an Abgasturbolader defekt

Liebherr-Kundendienst kontaktieren.

Abgase sind blau.

Kurbelgehäuseentlüftung defekt

Prüfen, bei Bedarf ersetzen.

Abgase sind blau.

Kolbenringe defekt

Liebherr-Kundendienst kontaktieren.

Bei Bedarf Lüfterantrieb ersetzen.

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Malfunction / error

Cause

Remedy

Abgase sind blau.

Ventilschaftdichtungen defekt

Liebherr-Kundendienst kontaktieren.

Abgase sind weiß.

Einspritzung verzögert

Liebherr-Kundendienst kontaktieren.

Abgase sind weiß.

Heizflansch defekt (Temperatur < -10 °C)

Heizflansch prüfen. Bei Bedarf Heizflansch ersetzen.

Abgase sind weiß.

Kühlmittel in Brennraum

Liebherr-Kundendienst kontaktieren.

Motor nagelt.

Verbrennungsstörungen

Liebherr-Kundendienst kontaktieren.

Motor klopft.

Injektor beschädigt oder verkokt

Liebherr-Kundendienst kontaktieren.

Motor klopft.

Lagerschaden

Liebherr-Kundendienst kontaktieren.

Motor klopft.

Kolbenringe verschlissen, Kolbenringe gebrochen, Kolben gefressen

Liebherr-Kundendienst kontaktieren.

Abnormale Geräusche

Undichtheiten an Ansaugleitungen und Abgasleitungen verursachen Pfeifgeräusche.

Undichtheit beseitigen. Bei Bedarf Dichtung ersetzen.

Abnormale Geräusche

Fremdkörper in Verdichter oder Turbine

Liebherr-Kundendienst kontaktieren.

Abnormale Geräusche

Anstreifen des Turbinenrades oder Verdichterrades am Gehäuse

Liebherr-Kundendienst kontaktieren.

Abnormale Geräusche

Festgefressene Lager der rotierenden Teile

Liebherr-Kundendienst kontaktieren.

Schmieröldruck zu niedrig

Ölstand in Ölwanne zu niedrig

Ölstand korrigieren.

Schmieröldruck zu niedrig

Motoröl zu dünnflüssig

Öl ablassen. Öl einfüllen.

Ursache der Ölverdünnung feststellen und beheben.

Schmieröldruck zu niedrig

Öldruckgeber defekt

Motorölsystem prüfen.

Beschädigten Öldruckgeber ersetzen.

Schmieröldruck zu niedrig

Endregelventil defekt

Liebherr-Kundendienst kontaktieren.

Schmieröldruck zu niedrig

Endregelventil verschmutzt

Liebherr-Kundendienst kontaktieren.

Schmieröldruck zu niedrig

Lagerspiel infolge Abnützung zu groß oder Lagerschaden

Liebherr-Kundendienst kontaktieren.

Schmieröldruck zu niedrig

Ölpumpe defekt

Ölpumpe prüfen. Ölpumpe bei Bedarf ersetzen.

Schmieröldruck zu niedrig

Ölfilter verstopft

Ölfilter wechseln.

Schmieröldruck zu niedrig

Öldruck-Regelventil defekt

Liebherr-Kundendienst kontaktieren.

copyright © Liebherr Machines Bulle SA 2020

D944 A7-00 / LWE / 2019030002

119

Malfunctions

Operator's manual

Faults - Cause - Remedy

Malfunction / error

Cause

Remedy

Motoröl in Kühlsystem

Ölkühler oder Ölkühlerplatte leckt

Liebherr-Kundendienst kontaktieren.

Kühlmittel in Motoröl

O-Ringe an Zylinderlaufbuchsen lecken

Liebherr-Kundendienst kontaktieren.

Kühlmittel in Motoröl

Ölkühler oder Ölkühlerplatte leckt

Liebherr-Kundendienst kontaktieren.

copyright © Liebherr Machines Bulle SA 2020

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D944 A7-00 / LWE / 2019030002

7 Tools and devices

7.1 Tools 7.1.1 Special tool Graphic representation

Description

Required number

Identification number

Turning device

1

0524045

Turning device

1

10118801

Turning device

1

10116805

Drain hose

1

12690422

Drain hose 90°

1

12690423

Tab. 31: 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

copyright © Liebherr Machines Bulle SA 2020

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Tools and devices

Operator's manual

Tools

Locking agent Loctite 243

811205708

50 ml

Tab. 32: Locking agent Sealant Designation Identification number Quantity Loctite 5910 10354595

300 ml

Tab. 33: Sealant Lubricants Designation

Identification number Quantity

NBU 30 grease 10285708

1 kg

Motorex 14

10002552

850 g

Altemp QNB 50 10490569

80 g

Tab. 34: 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 device and falling of the engine!

Leads to death or serious injuries.

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

Observe maximum weight for lifting points.

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

Use a Liebherr lifting traverse. (For more information see: 7.2.1 Lifting traverse with three-pointraising (basic version), page 123.)

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. 98: 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

copyright © Liebherr Machines Bulle SA 2020

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123

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

Chain suspension T-slide piece Attachment point sticker (see: fig. 100, page 125)

4 5

I-reception tube I-slide piece

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

copyright © Liebherr Machines Bulle SA 2020

124

D944 A7-00 / LWE / 2019030002

Operator's manual

Tools and devices Devices

Fig. 100: Attachment point sticker

7.2.2 Lifting traverse with two-point-raising

Fig. 101: Lifting traverse with two-point-raising 1 2

I-slide piece I-reception tube

3

Chain suspension

copyright © Liebherr Machines Bulle SA 2020

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125

Tools and devices

Operator's manual

Devices

7.2.3 Engine assembly stand

Fig. 102: 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. 35: Technical data

copyright © Liebherr Machines Bulle SA 2020

126

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Operator's manual

Tools and devices Devices

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

Leads to death or serious injuries.

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

Observe maximum weight for lifting points.

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

Use a Liebherr lifting traverse. (For more information see: 7.2.1 Lifting traverse with three-pointraising (basic version), page 123.)

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. 36: 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. 37: Tightening instruction

copyright © Liebherr Machines Bulle SA 2020

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127

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. 38: Tightening instruction

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128

D944 A7-00 / LWE / 2019030002

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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129

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. 39: 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. 40: 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. 41: 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. 42: 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. 43: Tightening torques for locking screws and banjo bolts

8.1.3 Standard torques for metric flange connections

Fig. 106: Overview of flange connections

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Operator's manual

Appendix Tightening torques

Note Tightening torques apply for mating material: Steel.

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

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

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

Thread Y

Form A with sealing ring

Form B with sealing edge

6

Form E with flat (ED) seal

Form F with oring

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

M 10 x 1.0

9

7

18

13

18

13

15

11

8

M 12 x 1.5

20

15

30

22

25

18

25

18

10

M 14 x 1.5

35

26

45

33

45

33

35

26

12

M 16 x 1.5

45

33

65

48

55

41

40

30

15

M 18 x 1.5

55

41

80

59

70

52

45

33

18

M 22 x 1.5

65

48

140

103

125

92

60

44

22

M 26 x 1.5

90

66

190

140

180

133

100

74

28

M 33 x 2.0

150

111

340

251

310

229

160

118

35

M 42 x 2.0

240

177

500

369

450

332

210

155

42

M 48 x 2.0

290

214

630

465

540

398

260

192

Tab. 44: 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. 45: Metric screw connection series L (light), part 2

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133

Appendix

Operator's manual

Tightening torques

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

Thread Y

Form A with sealing ring

Form B with sealing edge

Form E with flat (ED) seal

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

6

M 12 x 1.5

20

15

35

26

40

30

8

M 14 x 1.5

35

26

55

41

40

30

10

M 16 x 1.5

45

33

70

52

70

52

12

M 18 x 1.5

55

41

110

81

90

66

14

M 20 x 1.5

55

41

150

111

125

92

16

M 22 x 1.5

65

48

170

125

135

100

20

M 27 x 2.0

90

66

270

199

180

133

25

M 33 x 2.0

150

111

410

302

310

229

30

M 42 x 2.0

240

177

540

398

450

332

38

M 48 x 2.0

290

214

700

516

540

398

Tab. 46: 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. 47: 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

Form E with flat (ED) seal

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

6

G 1/8A

9

7

18

13

18

13

8

G 1/4A

35

26

35

26

35

26

10

G 1/4A

35

26

35

26

35

26

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Operator's manual

Appendix Tightening torques

Pipe diameter X

Thread Y Form A with sealing ring

Form B with sealing edge

Form E with flat (ED) seal

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

12

G 3/8A

45

33

70

52

70

52

15

G 1/2A

65

48

140

103

90

66

18

G 1/2A

65

48

100

74

90

66

22

G 3/4A

90

66

180

133

180

133

28

G 1A

150

111

330

243

310

229

35

G 1 1/4A

240

177

540

398

450

332

42

G 1 1/2A

290

214

630

465

540

398

Tab. 48: 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. 49: 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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135

Appendix

Operator's manual

Tightening torques

Pipe diameter X

38

Thread Y Form A with sealing ring

G 1 1/2A

Form B with sealing edge

Form E with flat (ED) seal

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

290

214

700

516

540

398

Tab. 50: 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. 51: 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. 52: 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. 107: 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. 53: 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. 108: Triple lock flange connections

copyright © Liebherr Machines Bulle SA 2020

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Appendix

Operator's manual

Tightening torques

Series

Pipe diameter X mm

Standard thread Z

inch

Nm

UN/UNF

ft/lb Steel

Nm

ft/lb

Stainless steel

4

6

1/4

7/17-20

15

11

30

22

5

8

5/16

1/2-20

20

15

40

30

6

10

3/8

9/16-18

30

22

60

44

8

12

1/2

3/4-16

60

44

115

85

10

14, 15, 16

5/8

7/8-14

75

55

145

107

12

18, 20

3/4

1 1/16-12

110

81

180

133

16

22

7/8

1 5/16-12

135

100

225

166

25

1

1 5/16-12

175

129

255

188

1 5/8-12

260

192

295

218

1 5/8-12

260

192

295

218

1 7/8-12

340

251

345

254

1 7/8-12

340

251

345

254

2 1/4-12

380

280

400

295

2 1/2-12

450

332

470

347

28 20

30, 32

1 1/4

35 24

38

28

42

32

50

1 1/2

2

Tab. 54: 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. 109: VSTI screw plugs

Standard thread

Nm

ft/lb

Standard thread

Nm

ft/lb

M 10 x 1

10

7

M 26 x 1.5

100

74

M 12 x 1.5

20

15

M 27 x 2

120

89

M 14 x 1.5

30

22

R 3/4”

120

89

M 16 x 1.5

40

30

M 30 x 1.5

120

89

M 18 x 1.5

50

37

M 33 x 2

200

148

copyright © Liebherr Machines Bulle SA 2020

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Operator's manual

Appendix Tightening torques

Standard thread

Nm

ft/lb

Standard thread

Nm

ft/lb

M 20 x 1.5

60

44

M 38 x 1.5

280

207

M 22 x 1.5

80

59

M 42 x 2

350

258

M 24 x 1.5

90

66

M 48 x 2

400

295

Tab. 55: Standard torques for VSTI screw plugs

copyright © Liebherr Machines Bulle SA 2020

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Appendix

Operator's manual

Tightening torques

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