Liebherr Diesel engine D956 A7-05 LHB Operator's Manual

Operator's manual Diesel engine D956 A7-05 / LHB From serial number 2019060001

en

Document ID Order number: Issued: Version: Author:

ORIGINAL OPERATOR'S MANUAL 13454733 10.06.2020 00 LMB / KD32

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

Diesel engine D956 A7-05 / LHB 2019060001

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

Manuafactorer's representative Liebherr-Components Colmar SAS 43, rue Frédéric Hartmann – CS 10106 68025 Colmar Cedex France

Only for the United States

WARNING

WARNING

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

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

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

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

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

- Do not modify or tamper with exhaust system.

- Do not idle the engine except as necessary.

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

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

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

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

3

Operator's manual

copyright © Liebherr Machines Bulle SA 2020

4

D956 A7-05 / LHB / 2019060001

Change history

Version From serial number Changes included 00

2019060001

Issue

Document newly created 6/10/2020

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

5

Operator's manual

copyright © Liebherr Machines Bulle SA 2020

6

D956 A7-05 / LHB / 2019060001

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.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

7

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.

copyright © Liebherr Machines Bulle SA 2020

8

D956 A7-05 / LHB / 2019060001

Operator's manual

Preface Graphic symbols in these instructions

Graphic symbols in these instructions Symbol

Meaning Note Identifies useful information and tips.

Prerequisite Identifies conditions for the following action steps.

Call to action Identifies action steps.

Result Identifies results of one or more action steps.

–

Itemization Identifies individual points of a list.

Graphic symbols

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

9

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.”

copyright © Liebherr Machines Bulle SA 2020

10

D956 A7-05 / LHB / 2019060001

Contents

1

Product description

17

1.1

Technical description

17

1.1.1

Engine components

17

1.1.2

Exhaust aftertreatment system SCRFilter (single-flow)

19

1.1.3

Engine type itemization

28

1.1.4

Company nameplate

29

1.1.5

Firing order, cylinder designation and engine serial number

31

1.1.6

Direction of rotation

31

1.1.7

Engine control unit type plate ECU3

32

1.1.8

Exhaust aftertreatment system type plate

33

1.1.9

DOC, mixing pipe and sensor pipe

34

1.2

2

1.1.10 Exhaust aftertreatment system SCRFilter (single-flow)

35

Technical data

36

1.2.1

Diesel engine D956 A7-05

36

1.2.2

Valve clearance with ABS

36

1.2.3

Coolant thermostat

36

Safety

37

2.1

Labeling of warnings

37

2.1.1

37

Additional labels

2.2

Target group

38

2.3

Intended use

38

2.4

Foreseeable misuse

38

2.5

General safety instructions

39

2.6

Preventing personal injuries

41

2.6.1

Bruises

41

2.6.2

Burns and scalds

41

2.6.3

Fires and explosions

41

2.6.4

Poisoning

41

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

11

Contents

Operator's manual

5

42

2.6.6

Electrical energy

42

2.6.7

Danger due to noise

42

Personal protective equipment

42

2.8

Operating areas and maintenance areas

43

2.8.1

Safety instructions

43

2.8.2

Operating areas

44

2.8.3

Maintenance areas

44

2.8.4

Securing and releasing the diesel engine against accidental start-up

45

2.8.5

Emergency stop

46

Signage

46

2.10 Preventing property damage

47

Transport and storage

49

3.1

Dimensions and weights

49

3.2

Lifting the engine

50

3.3

Transport

52

3.3.1

Transport attachment

52

3.3.2

Transport device

53

3.4

4

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

2.7

2.9

3

2.6.5

Storage

55

3.4.1

Storage

55

3.4.2

Storage time

59

Operation

61

4.1

Preliminary work for the initial commissioning of the engine

61

4.2

Starting the engine

62

4.3

Turning off the engine

64

Maintenance

65

5.1

Maintenance schedule

65

5.2

Preliminary work

68

5.2.1

Bringing the engine into maintenance position

68

5.2.2

As needed

68

5.3

Diesel engine

70

5.3.1

70

Checking the system for leaks, contamination and damage

copyright © Liebherr Machines Bulle SA 2020

12

D956 A7-05 / LHB / 2019060001

Operator's manual

Contents

5.4

5.5

5.6

5.7

5.8

5.9

5.3.2

Checking the V-ribbed belt for damage

70

5.3.3

Checking the V-ribbed belt for tension

71

5.3.4

Checking the belt drive

73

5.3.5

Replacing the belt drive

76

5.3.6

Checking the engine mount

80

5.3.7

Replacing the viscous damper

80

5.3.8

Checking the intake system for leaks and damage

81

5.3.9

Checking the exhaust system

83

Engine oil system

84

5.4.1

Checking the engine oil system for leaks and damage

84

5.4.2

Checking the engine oil level

87

5.4.3

Changing the engine oil

88

5.4.4

Replacing the oil separator filter insert

92

Cylinder head

95

5.5.1

95

Checking and setting the valve clearance

Cooling system

108

5.6.1

Checking the cooling system and heating system for leaks and damage

108

5.6.2

Checking the coolant level

109

5.6.3

Checking the concentration of the antifreeze agent in the coolant

109

5.6.4

Replacing the coolant

110

Fuel system

113

5.7.1

Checking the fuel system for leaks and damage

113

5.7.2

Checking the water separator on the fuel prefilter

114

5.7.3

Draining the water from the water separator in the fuel prefilter

114

5.7.4

Draining water and sediment from the fuel tank

114

5.7.5

Replacing the fuel prefilter

114

5.7.6

Reducing the pressure in the fuel system

115

5.7.7

Replacing the fuel fine filter

115

5.7.8

Ventilating the fuel system

116

Air filter

117

5.8.1

Checking the air filter low pressure indicator

117

5.8.2

Cleaning the air filter dust discharge valve

117

5.8.3

Replacing the dry air filter main element

117

5.8.4

Replacing the dry air filter safety element

117

Electrical system

118

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

13

Contents

Operator's manual

5.9.1

Checking the batteries

118

5.9.2

Checking the cable connections

118

5.9.3

Checking the engine control unit bearings for damage

118

5.9.4

Checking sensors, actuators, cable holders and plugs

119

5.9.5

Checking the heating flange

120

5.9.6

Replacing the heating flange

123

5.10 Exhaust aftertreatment system

6

7

5.10.1 Checking the exhaust aftertreatment system for leaks and damage

125

5.10.2 SCRFilter (single-flow)

125

5.10.3 Check components

127

5.10.4 SCRFilter (single-flow)

127

5.10.5 Cleaning the SCR filter module

128

5.11 Lubricants and operating fluids

139

5.11.1 Fill quantities

139

5.11.2 Engines oil for diesel engines with emission limit stage (EU) 2016/1628 stage V

139

5.11.3 Coolant

140

5.11.4 Fuel for diesel engines with emission limit stage (EU) 2016/1628 stage V

141

Malfunctions

143

6.1

143

Faults - Cause - Remedy

Tools and devices

149

7.1

149

7.2

8

125

Tools 7.1.1

Special tool

149

7.1.2

Operating material

149

7.1.3

Diagnostic tools

150

Devices

151

7.2.1

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

151

7.2.2

Lifting traverse with two-point-raising

153

7.2.3

Engine assembly stand

154

7.2.4

Transport device

155

Appendix

157

8.1

157

Tightening torques

copyright © Liebherr Machines Bulle SA 2020

14

D956 A7-05 / LHB / 2019060001

Operator's manual

Contents

8.1.1

For hex bolts / cylinder screws / external hex bolts

157

8.1.2

For locking screws and banjo bolts

159

8.1.3

Standard torques for metric flange connections

160

8.1.4

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

161

8.1.5

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

162

8.1.6

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

162

8.1.7

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

163

8.1.8

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

164

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

15

Contents

Operator's manual

copyright © Liebherr Machines Bulle SA 2020

16

D956 A7-05 / LHB / 2019060001

1 Product description

1.1 Technical description 1.1.1 Engine components

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

Viscous damper Coolant pump Deflection pulley Alternator Air conditioning compressor

6 7 8 9

Transport device Exhaust manifold Exhaust gas turbocharger Oil cooler

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

17

Product description

Operator's manual

Technical description

Fig. 2: Flywheel side 1 2 3 4 5

Crankcase breather system Fuel high pressure pump Fuel lines Cylinder head cover Heating flange

6 7 8 9 10

Air intake pipe Charge air pipe Oil dipstick Engine control unit Oil pan

copyright © Liebherr Machines Bulle SA 2020

18

D956 A7-05 / LHB / 2019060001

Operator's manual

Product description Technical description

1.1.2 Exhaust aftertreatment system SCRFilter (single-flow)

Fig. 3: Exhaust aftertreatment system, reduction agent pump and reduction agent injector.

1 2 3 4 5 6 7

Sensor pipe Outlet module Reduction agent injector Mixing pipe Diesel oxidation catalyst (DOC) Differential pressure sensor Inlet module

8 9 10 11 12 13

Filter module NOx sensor SCR NH3 sensor Control unit SCR NH3 sensor Temperature sensor Reduction agent pump

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

19

Product description

Operator's manual

Technical description

17 18

16

T

T

1

22

3 15

NOx

31

19

21

14 28

33 10 27

6

9

NOx NH3

11

29 8

4

T

PAir

13

PT DEF

26 25 24

20 32

12

30 dP

23 7 2 5 Fig. 4: Exhaust aftertreatment system functional diagram 1

Coolant supply

12

2

Coolant return

13

3

Compressed air

14

4 5

Ventilation Reduction agent extraction module Reduction agent suction line heating system

15 16

Coolant control valve Coolant control valve Reduction agent pump Air pressure sensor Air control valve

18 19 20 21 22

6

7 8 9 10 11

17

Reduction agent temperature pressure sensor Reduction agent pump module Reduction agent pressure line heating system Reduction agent injector Mixing pipe temperature sensor Diesel oxidation catalyst (DOC) inlet temperature sensor Inlet NOX sensor Exhaust inlet Exhaust outlet Mixing pipe Diesel oxidation catalyst (DOC)

23

Differential pressure sensor

24

SCR NH3 sensor outlet

25

Outlet NOX sensor

26 27

Temperature sensor outlet Air line

28

Coolant line

29 30 31 32 33

Reduction agent pressure line Differential pressure line Engine exhaust pipe Control unit SCR NH3 sensor Filter module

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

copyright © Liebherr Machines Bulle SA 2020

20

D956 A7-05 / LHB / 2019060001

Operator's manual

Product description Technical description

Lamp

Designation

Meaning

EESF lamp (Engine emission system failure)

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

MIL lamp (Malfunction Indicator Lamp)

Reduction agent lamp

Filter module lamp (filter module)

Illuminates depending on the soot load

AWL lamp (Amber Warning Lamp)

Action required during the next maintenance

RSL lamp (Red Stop Lamp)

Engine stop required

Manual interruption or termination of the regeneration

HEST lamp (High Exhaust System Temperature)

High exhaust temperatures

Torque limitation to relieve the exhaust aftertreatment system.

Tab. 1: Exhaust aftertreatment system control and warning lamps

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

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

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

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

21

Product description

Operator's manual

Technical description

Note The restrictions occur in stages.

Display (pictograms are examples)

MIL off

Reducing agent lights up yellow continuously.

Acoustic signal

MIL flashes or lights up yellow continuously

System status

Restrictions

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

No restriction

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

Low power limitation

Remedy

Acoustic signal Reducing agent lights up yellow continuously.

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

MIL flashes or lights up yellow continuously.

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

Acoustic signal Reducing agent flashes or lights up red continuously.

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

MIL flashes or lights up red continuously.

Acoustic signal Reducing agent flashes or lights up red continuously.

Tab. 2: Exhaust aftertreatment system warning and malfunction strategies

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

copyright © Liebherr Machines Bulle SA 2020

22

D956 A7-05 / LHB / 2019060001

Operator's manual

Product description Technical description

100% 75%

20% 30 min

10 min < 10%

< 5%

~2.5%

0%

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

Reduction agent fill level Available torque

3

Available torque curve

100% 75%

20% 0 min

60 min

70 min

170 min

200 min

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

Time elapsed Available torque

3 4

Occurrence of the error Torque reduction curve

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

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

23

Product description

Operator's manual

Technical description

45 mph 73 km/h

5 mph 7 km/h

30 min

10 min < 10%

< 5%

~2.5%

0%

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

Reduction agent level Available speed

3

Speed curve

no limit 45 mph 73 km/h

5 mph 7 km/h

0 min

60 min

70 min

170 min

200 min

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

Time elapsed Speed

3 4

Occurrence of the error Speed curve

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

copyright © Liebherr Machines Bulle SA 2020

24

D956 A7-05 / LHB / 2019060001

Operator's manual

Product description Technical description

100 80 60 40 20 0

0

20

40

60

80

100

120

140

160

180

200

220

240

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

Time elapsed

3

2

Speed

4

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

Use / handling of reduction agent NOTICE Escaping reducing agent!

Damage to painted surfaces or aluminum surfaces.

Rinse affected surfaces with water immediately.

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

Legally prescribed emission limits are not observed.

Destruction of the exhaust aftertreatment system!

Keep the reducing agent absolutely pure.

Make sure that no dirt gets into the reducing agent.

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

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

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

Destruction of the diesel engine or the exhaust aftertreatment system.

Keep the reducing agent absolutely pure.

Do not reuse reducing agent that has been drained.

NOTICE Operation without reducing agent!

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

Operator is liable to prosecution.

Operate the system with reducing agent.

Refill the reducing agent on time.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

25

Product description

Operator's manual

Technical description

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

Filter module In order to reduce the soot particles in the diesel engine exhaust to a legally permissible level, a filter module is necessary. The filter module filters the soot particles in the exhaust gas flow and stores them. If the temperature of the exhaust gas flow is high enough, the stored soot particles in the filter are removed.

So that the filter module does not become clogged and the exhaust back pressure in the diesel engine does not get too high, the particles stored in the filter must be removed from time to time.

This process is called regeneration.

Ash is produced through the running of the engine, which is deposited in the filter. It can only be removed by cleaning.

Passive regeneration Depending on the design and load of the diesel engine, the exhaust temperature is high enough to remove the soot particles during operation. No intervention is required by the engine or the user.

This ideal condition is described as “passive regeneration”.

Active regeneration If too many soot particles are stored in the filter module, the back pressure in the exhaust gas flow increases. An “active regeneration” of the filter module is required to reduce the particle load.

For active regeneration, a distinction is made between – automatic regeneration (device in driving condition) – manual regeneration (device standstill) Manual regeneration is initiated by the operator by means of a switch.

The duration of the manual regeneration is approx. 45 minutes. Depending on the application, a fuel post-injection can be used in order to achieve the required exhaust temperature for the active regeneration. The injection quantity is regulated to achieve the exothermic reaction of the exhaust in the diesel oxidation catalyst. The soot particles in the filter module are thereby burned up and the filter module is regenerated.

Regeneration switch Regeneration switch

Tab. 3 The device operator can initiate the manual (active) regeneration using the regeneration switch.

The engine speed is independently controlled by the engine control unit during this process and the device must remain at a standstill. The required regeneration time depends on the filter module load condition, the ambient temperature and the exhaust temperature. The normal regeneration time is 45 minutes.

copyright © Liebherr Machines Bulle SA 2020

26

D956 A7-05 / LHB / 2019060001

Operator's manual

Product description Technical description

Note Only initiate manual regeneration when it is required by the displays (illumination) of the filter module lamp

.

Lamp Position Meaning Active regeneration is automatically initiated.

Center The switch should be at the Automatic regeneration position during each engine start 1

Suppress or terminate the filter module regeneration (until the switch is brought back to the center - or position 2).

Application in potentially flammable environments, for example Manual filter module regeneration is initiated

2 Tab. 4

Regeneration of the filter module The filter module must be regenerated after a certain soot load.

The following table explains in which situations which types of regeneration can be initiated.

Stage

1

2

3

4

Soot load of the filter module in gr/l

< 3.8

3.8 - < 5

5.0 - < 6.5

6.5 - < 7

7

Soot load of the filter module in %

1 %20 %

20 % < 40 %

80 % < 100 %

100 %

Filter module lamp

40 % < 60 %

60 % < 80 %

5

Off

AWL lamp

Off

RSL lamp

Off

Torque limitation Off 50 % Suppression of the automatic regeneration

The driver can prevent the automatic regeneration.

Off

Regeneration initiated by driver

Off

The driver can initiate a regeneration.

Off

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

27

Product description

Operator's manual

Technical description

Stage

1

Regeneration initiated

by Liebherr service

2

3

4

5

Regeneration can be initiated through diagnostics tool.

without post-injec- active during manual regeneration or regeneration initiated by service tion

HEST lamp

with postinjection

active during manual regeneration, automatic regeneration or regeneration initiated by service

Tab. 5: Regeneration of the filter module Ash load of the filter module Operating time of the filter module in hours

0

1

2

< 5000

5000 - < 6000

6000

AWL lamp

Off

Torque limitation Off Torque limitation to 50% Tab. 6: Ash load of the filter module For optimum filter module operation, it is recommended not to interrupt a manually running regeneration. However, if there is a risk of fire, for example, a manual regeneration must be prevented.

1.1.3 Engine type itemization Description D 95 6 A7 -05 Engine type D

Engine type: D = diesel engine 95

Family (l/cylinder): 95: 2 l/cylinder 6

Number of cylinders A7

Injection system: A7 = Common Rail System Type, emission standard and exhaust aftertreatment system: -05 Emission standard: Stage V Exhaust aftertreatment system: SCRFilter (Selective Catalytic Reduction with diesel particulate filter)

Tab. 7: Engine type itemization

copyright © Liebherr Machines Bulle SA 2020

28

D956 A7-05 / LHB / 2019060001

Operator's manual

Product description Technical description

1.1.4 Company nameplate

Fig. 47: Company nameplate 1 2 3 4 5 6 7 8 9 10

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

11 12 13 14 15 16 17 18 19

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

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

29

Product description

Operator's manual

Technical description

Attachment point

Fig. 48: Company nameplate on the engine 1

Company nameplate on the air intake pipe

2

Company nameplate on the crankcase

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

2018 06 0001 Engine serial number 2018

Year of manufacture 06

Type series: 04 = D956 / 06 = D966 0001 Sequential production number

Tab. 8: Engine serial number

copyright © Liebherr Machines Bulle SA 2020

30

D956 A7-05 / LHB / 2019060001

Operator's manual

Product description Technical description

1.1.5 Firing order, cylinder designation and engine serial number

Fig. 49: Cylinder designation, engine serial number (example) and firing order 1 2

Engine serial number Firing order

3

Cylinder designation

1.1.6 Direction of rotation

1

2

3

4

5

6

Fig. 50: Cylinder designation and direction of rotation 1

Flywheel side

2

Unit carrier side

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

Viewed from the flywheel 1, the crankshaft turns counterclockwise.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

31

Product description

Operator's manual

Technical description

1.1.7 Engine control unit type plate ECU3

Fig. 51: Engine control unit type plate ECU3 (example) 1 2 3 4

Creation date 2D bar code Engine type Control unit designation

5 6 7 8

Engine serial number Control unit identification number Certification identification number Parameter set identification number

Attachment point

Fig. 52: Attachment point 1

Engine control unit type plate

copyright © Liebherr Machines Bulle SA 2020

32

D956 A7-05 / LHB / 2019060001

Operator's manual

Product description Technical description

1.1.8 Exhaust aftertreatment system type plate

Ý«­¬±³»® ×Ü

ïïíèîëêè

ÍÛÎ×ßÔ Ò±ò

ÔÎßðëêëçî

ÍËÐÐÔ×ÛÎ ÐßÎÌ Ò±ò ú ×ÍÍËÛ ÔÛÊÛÔ

ÉÍÈÈïêê

ÓßÒËÚßÝÌËÎÛ ÜßÌÛ

ÜÜ ñ ÓÓ ñ ÇÇ

Fig. 53: Sample type plate 1 2 3

DMC code Identification number Serial number

4 5

Supplier part number Date of manufacture

Fig. 54: Sample type plate for spacer 1

Identification number

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

33

Product description

Operator's manual

Technical description

1.1.9 DOC, mixing pipe and sensor pipe

Fig. 55: Type plate on DOC, mixing pipe and sensor pipe 1

Type plate for individual components

copyright © Liebherr Machines Bulle SA 2020

34

D956 A7-05 / LHB / 2019060001

Operator's manual

Product description Technical description

1.1.10 Exhaust aftertreatment system SCRFilter (single-flow)

Fig. 56: Type plate on inlet module, filter module and outlet module 1

Type plate for individual components

2

Type plate for complete system

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

35

Product description

Operator's manual

Technical data

1.2 Technical data 1.2.1 Diesel engine D956 A7-05 Description

Unit Value

Construction

In-line diesel engine

Number of cylinders

6

Firing order

1–5–3–6–2–4

Hole

mm 130

Stroke

mm 150

Displacement

l 11,95

Compression ratio

17,5:1

Direction of rotation of the diesel engine

Viewed from the flywheel: counterclockwise

Rated power

see company nameplate

Rated speed

see company nameplate

1.2.2 Valve clearance with ABS Description

Unit Value

Valve clearance, inlet, cold

mm 0.3

Valve clearance, outlet, cold

mm 0.6

Auxiliary brake system, cold

mm 0.4

1.2.3 Coolant thermostat Description

Unit Value

Start of opening

°C 82

Completely opened

°C 92

copyright © Liebherr Machines Bulle SA 2020

36

D956 A7-05 / LHB / 2019060001

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. 9 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. 10

2.1.1 Additional labels Note Identifies useful information and tips.

Tab. 11

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

37

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

copyright © Liebherr Machines Bulle SA 2020

38

D956 A7-05 / LHB / 2019060001

Operator's manual

Safety General safety instructions

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

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

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

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

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

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

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

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

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

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

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

• Observe the generally recognized safety and occupational health rules.

• Observe the operator's manual.

– Make sure that the personnel wears the prescribed work clothing. (For more information see: 2.7 Personal protective equipment, page 42.)

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

– Keep the workplace clean and orderly.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

39

Safety

Operator's manual

General safety instructions

– – – – – –

Make preparations for emergencies that could occur.

Have a fire extinguisher and first aid kit ready.

Have emergency telephone numbers ready.

Make sure that the workplace has sufficient lighting.

Perform installation work only when the engine is secured.

Ensure that the engine is not started by unauthorized individuals.

copyright © Liebherr Machines Bulle SA 2020

40

D956 A7-05 / LHB / 2019060001

Operator's manual

Safety Preventing personal injuries

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

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

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

– Observe the regulations on the lifting points.

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

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

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

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

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

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

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

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

– Avoid contact with parts carrying coolant.

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

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

2.6.3 Fires and explosions – – – –

Do not smoke in the immediate vicinity of the engine.

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

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

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

– Remove rags that are soaked with flammable liquids.

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

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

– Never ingest operating fluids.

– Do not use beverage bottles to store operating fluids.

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

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

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

– Protect hands, face and body against escaping liquids when searching for leaks on lines and hoses that are under pressure. (For more information see: 2.7 Personal protective equipment, page 42.)

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

41

Safety

Operator's manual

Personal protective equipment

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

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

– Check the pressure reduction with the diagnostics software.

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

– Do not open any pressurized fuel lines or hoses.

– Do not disconnect any pressurized fuel lines or hoses.

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

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

– Do not touch any live parts.

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

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

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

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

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

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

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

copyright © Liebherr Machines Bulle SA 2020

42

D956 A7-05 / LHB / 2019060001

Operator's manual

Safety Operating areas and maintenance areas

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

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

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

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

Hearing protection – Protection against noise

Gas detector – Protection against escaping gases

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

– Wear personal protective equipment.

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

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

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

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

43

Safety

Operator's manual

Operating areas and maintenance areas

– Wear personal protective equipment.

– Let the engine cool down sufficiently.

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

– Wear personal protective equipment.

2.8.2 Operating areas A

D

B

B

B

B

C

E

a

b

Fig. 69: 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.

copyright © Liebherr Machines Bulle SA 2020

44

D956 A7-05 / LHB / 2019060001

Operator's manual

Safety Operating areas and maintenance areas

A

D

B

B

B

B

C

E

a

b

Fig. 70: 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

D956 A7-05 / LHB / 2019060001

45

Safety

Operator's manual

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.

copyright © Liebherr Machines Bulle SA 2020

46

D956 A7-05 / LHB / 2019060001

Operator's manual

Safety Preventing property damage

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

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

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

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

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

– Replace removed, not reusable parts.

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

– Replace self-locking screwed assemblies.

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

– Use lint-free cleaning cloths.

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

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

– Remove covers or adhesives after cleaning.

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

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

– Use suitable test leads for measurements on plug connections.

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

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

– Disconnect the negative pole first and connect it last.

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

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

47

Safety

Operator's manual

Preventing property damage

copyright © Liebherr Machines Bulle SA 2020

48

D956 A7-05 / LHB / 2019060001

3 Transport and storage

3.1 Dimensions and weights

2

1

3

Fig. 76: Dimensions 1 2

Width Height

3

Length

Description

Unit Value

Length

mm 1468

Width

mm 931

Height

mm 1182

Engine weight (without coolant, without engine oil)

kg 1262

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

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

49

Transport and storage

Operator's manual

Lifting the engine

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

Will lead to death or serious injuries due to crushing.

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

Observe maximum weight for lifting points.

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

Use a Liebherr lifting traverse. (For more information see: 7.2.1 Lifting traverse with three-pointraising (basic version), page 151.)

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.

copyright © Liebherr Machines Bulle SA 2020

50

D956 A7-05 / LHB / 2019060001

Operator's manual

Transport and storage Lifting the engine

max.10°

max.10°

4 1

4 5

3

4

5

3

3

5

1

1 1

2

B

2

2

D

C

A max.6° max.6° 5

2 E

F

Fig. 77: 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.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

51

Transport and storage

Operator's manual

Transport

3.3 Transport 3.3.1 Transport attachment

Fig. 78: 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.

copyright © Liebherr Machines Bulle SA 2020

52

D956 A7-05 / LHB / 2019060001

Operator's manual

Transport and storage Transport

3.3.2 Transport device Wood transport device DANGER Instability during transport!

Leads to death or serious injuries.

Only use the original transport device.

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

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

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

Observe the center of gravity.

Bolt the engine securely to the transport device.

Fig. 79: Wood transport device Only transport the engine using the transport device.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

53

Transport and storage

Operator's manual

Transport

Steel transport device DANGER Instability during transport!

Leads to death or serious injuries.

Only use the original transport device.

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

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

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

Observe the center of gravity.

Bolt the engine securely to the transport device.

Fig. 80: Steel transport device Only transport the engine using the transport device.

copyright © Liebherr Machines Bulle SA 2020

54

D956 A7-05 / LHB / 2019060001

Operator's manual

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

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

55

Transport and storage

Operator's manual

Storage

VCI film cover LxWxH ID no.

990x540x1300

11067328

2000x1500x2000

11826670

3200x1500x2000

11826671

540x350x540

11067327

350x250x550

11067326

850x650x800

10331822

Tab. 12: VCI film cover VCI bag LxW ID no.

300x200

11170517

345x260

11170521

Tab. 13: 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.

copyright © Liebherr Machines Bulle SA 2020

56

D956 A7-05 / LHB / 2019060001

Operator's manual

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. 14: 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.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

57

Transport and storage

Operator's manual

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)

copyright © Liebherr Machines Bulle SA 2020

58

D956 A7-05 / LHB / 2019060001

Operator's manual

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. 15: Storage time Observe the storage time.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

59

Transport and storage

Operator's manual

Storage

copyright © Liebherr Machines Bulle SA 2020

60

D956 A7-05 / LHB / 2019060001

4 Operation

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

Provide a suitable engine oil for the engine. (For more information see: 5.11.2 Engines oil for diesel engines with emission limit stage (EU) 2016/1628 stage V, page 139.)

Fill the oil.

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 109.)

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. (For more information see: 5.11.4 Fuel for diesel engines with emission limit stage (EU) 2016/1628 stage V, page 141.)

Fill the diesel fuel. (For more information see: 5.11.4 Fuel for diesel engines with emission limit stage (EU) 2016/1628 stage V, page 141.)

Ventilate the fuel system.

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.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

61

Operation

Operator's manual

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 61.)

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 65.)

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 143.)

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.

copyright © Liebherr Machines Bulle SA 2020

62

D956 A7-05 / LHB / 2019060001

Operator's manual

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 143.)

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 143.)

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

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

63

Operation

Operator's manual

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.

copyright © Liebherr Machines Bulle SA 2020

64

D956 A7-05 / LHB / 2019060001

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.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

65

Maintenance

Operator's manual

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

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

500 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

Daily

Diesel engine Check system for leaks, contamination and damage.

70

1000 h

Check V-ribbed belt.

70

1000 h

Check belt drive.

73

1000 h

Check the engine mount.

80

1000 h

Check intake system for leaks and damage.

81

1000 h 5000 h / every five years 10000 h

Check exhaust system.

83

Replace belt drive.

76

Replace viscous damper.

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

80

Check engine oil level.

87

Replace engine oil and oil filter. If necessary according to screen display.

88

10 h 10 h 2000 h / every two years 3000 h

84

Replace oil separator filter insert.

Cylinder head Check and set the valve clearance.

Cooling system Check coolant level.

92

Check cooling system and heating system for leaks and damage.

108

Check the concentration of the antifreeze agent.

109

Replace coolant.

110

10 h

Fuel system Check the water separator on the fuel prefilter.

114

50 h

Drain the water and sediment from the fuel tank.

114

500 h

Check fuel system for leaks and damage.

113

1000 h

Replace the fuel prefilter.

114

1000 h

115

10 h

Replace fuel fine filter.

Air filter Check the air filter low pressure indicator.

50 h

Clean the air filter dust discharge valve.

117

Replace the dry air filter main element.

117

Replace the dry air filter safety element.

Electrical system Check engine control unit bearings for damage.

117

3000 h 10 h 500 h 2000 h / annually 6000 h / every four years

500 h

95 109

117

118

copyright © Liebherr Machines Bulle SA 2020

66

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Maintenance schedule

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

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

50 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

1500 h

Check the batteries.

118

1500 h

Check the cable connections.

118

1500 h

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

119 120

10 h

Check heating flange, if present.

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

1000 h

Check components

127

5000 h

Replace filter module.

128

125

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

67

Maintenance

Operator's manual

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.

copyright © Liebherr Machines Bulle SA 2020

68

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Preliminary work

Removing the cover

Fig. 81: Removing the cover 1 2 3

External hex bolt (6x) Cover Distance bolt (6x)

4 5

Spacer (2x) Hex nut (2x)

Unscrew external hex bolt 1.

Remove cover 2.

Remove distance bolt 3.

Remove spacer 4.

Remove hex nut 5.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

69

Maintenance

Operator's manual

Diesel engine

5.3 Diesel engine 5.3.1 Checking the system for leaks, contamination and damage 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.

Check components for leaks.

If components are leaking: Do not start engine.

Replace components, see engine repair instruction or documentation from the system manufacturer.

Check components for proper fastening.

If components are loose: Do not start engine.

Tighten the components according to the tightening instruction.

Check components for damage.

If components are damaged: Do not start engine.

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

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

Cover is removed (if present). (For more information see: Removing the cover, page 69.)

Engine is in maintenance position. (For more information see: 5.2.1 Bringing the engine into maintenance position, page 68.)

copyright © Liebherr Machines Bulle SA 2020

70

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Diesel engine

Fig. 82: 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.

5.3.3 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.

Fig. 83: Tension pulley (self-tensioning) 1

Tension pulley (self-tensioning)

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

71

Maintenance

Operator's manual

Diesel engine

Replacing the (optional) air conditioning compressor V-ribbed belt Removing the V-ribbed belt Make sure that the following prerequisites are met: New V-ribbed belt is ready.

1/2” socket wrench transition piece (external square) with lever is available.

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

V-ribbed belt Tension pulley

3

Internal square

If a fan is present: Remove the fan.

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

Swivel back the tension pulley 2 counterclockwise against the spring force to the limit stop.

The V-ribbed belt 1 is free.

Remove the V-ribbed belt 1.

Turn back the tension pulley 2.

copyright © Liebherr Machines Bulle SA 2020

72

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Diesel engine

Installing the V-ribbed belt

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

V-ribbed belt Tension pulley

3

Internal square

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

Swivel back the tension pulley 2 counterclockwise against the spring force to the limit stop.

Install the V-ribbed belt 1.

Turn the tension pulley 2 back carefully.

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

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

– Engine is in maintenance position. (For more information see: 5.2.1 Bringing the engine into maintenance position, page 68.)

Checking the air conditioning compressor belt drive Removing the V-ribbed belt Make sure that the following prerequisites are met: Cover is removed (if present). (For more information see: Removing the cover, page 69.)

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

73

Maintenance

Operator's manual

Diesel engine

Fig. 86: Removing the V-ribbed belt 1 2

Internal square V-ribbed belt

3

Tension pulley (self-tensioning)

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

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

The V-ribbed belt 2 is relaxed.

Remove V-ribbed belt 2.

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

copyright © Liebherr Machines Bulle SA 2020

74

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Diesel engine

Checking the belt drive

Fig. 87: Components 1 2 3 4

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

5 6 7 8

Deflection pulley Coolant pump Deflection pulley Crankshaft belt pulley

Check components for damage.

If components are damaged: Do not start engine.

Replace damaged components, see repair instruction.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

75

Maintenance

Operator's manual

Diesel engine

Installing the V-ribbed belt

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

Internal square V-ribbed belt

3

Tension pulley (self-tensioning)

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

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

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

The V-ribbed belt 2 is tensioned.

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

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

– Engine is in maintenance position. (For more information see: 5.2.1 Bringing the engine into maintenance position, page 68.)

copyright © Liebherr Machines Bulle SA 2020

76

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Diesel engine

Replacing the air conditioning compressor belt drive Removing the V-ribbed belt Make sure that the following prerequisites are met: Cover is removed (if present). (For more information see: Removing the cover, page 69.)

Fig. 89: Removing the V-ribbed belt 1 2

Internal square V-ribbed belt

3

Tension pulley (self-tensioning)

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

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

The V-ribbed belt 2 is relaxed.

Remove V-ribbed belt 2.

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

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

77

Maintenance

Operator's manual

Diesel engine

Replacing the belt drive

Fig. 90 1 2

External hex bolt Tension pulley (self-tensioning)

3 4

External hex bolt (3x) Deflection pulley (3x)

Unscrew external hex bolt 1.

Remove tension pulley (self-tensioning) 2.

Unscrew external hex bolt 3.

Remove deflection pulleys 4.

Install new tension pulley (self-tensioning) 2.

Tighten external hex bolt 1 according to the tightening instruction.

Tightening instruction for M10x100 8.8 FLZN external hex bolt Lubricant

-

Locking agent

LOCTITE 243

Part contact surfaces

-

Screws

not reusable

Stage

Tightening torque

1.

60 ±5 Nm

Tab. 16: Tightening instruction Install deflection pulleys 4.

copyright © Liebherr Machines Bulle SA 2020

78

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Diesel engine

Tightening instruction for M10x1.5 external hex bolt Lubricant

-

Locking agent

LOCTITE 243

Part contact surfaces

-

Screws

not reusable

Stage

Tightening torque

1.

48 ±8 Nm

Tab. 17: Tightening instruction Tighten external hex bolt 3 according to the tightening instruction.

Installing the V-ribbed belt

Fig. 93: Installing the V-ribbed belt 1 2

Internal square V-ribbed belt

3

Tension pulley (self-tensioning)

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

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

79

Maintenance

Operator's manual

Diesel engine

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

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

The V-ribbed belt 2 is tensioned.

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

5.3.7 Replacing the viscous damper Removing the viscous damper Make sure that the following prerequisites are met: The V-ribbed belt is removed. (For more information see: Replacing the (optional) air conditioning compressor V-ribbed belt, page 72.)

Viscous damper is ready.

Fig. 94: Replacing the viscous damper 1

External hex bolt

2

Viscous damper

Unscrew external hex bolt 1 in reverse order of the tightening instruction. (see: tab. 18, page 81) Remove viscous damper 2.

Cleaning Clean contact surfaces of viscous damper 2.

Clean contact surfaces of belt pulley.

copyright © Liebherr Machines Bulle SA 2020

80

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Diesel engine

Installing the viscous damper Install viscous damper 2.

Tightening instruction for M10x40 10.9 FLZN external hex bolt Lubricant

-

Locking agent

-

Part contact surfaces

Degreased

Screws

reusable

Stage

Tightening torque

1.

Standard torque

Tightening sequence

Tab. 18: Tightening instruction 12564609_001 Tighten external hex bolt 1 according to the tightening instruction.

5.3.8 Checking the intake system for leaks and damage Note Control interval for this work is 1000 hours.

Perform maintenance work one time after 500 hours.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

81

Maintenance

Operator's manual

Diesel engine

Fig. 96: Checking the intake system 1 2 3

Intake manifold Intermediate flange/heating flange seal Intermediate flange/heating flange (optional)

4 5

Intake pipe Hex bolts

In addition, check the following components: Device side suction lines between intake pipe and exhaust gas turbocharger, see documentation from the device manufacturer.

Check all components of the intake system for damage, leaks and tight fit.

Check contact screws in the heating flange.

If parts are damaged: Do not start engine.

Replace damaged parts, see documentation from the device manufacturer.

Replace damaged parts, see repair instruction.

copyright © Liebherr Machines Bulle SA 2020

82

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Diesel engine

5.3.9 Checking the exhaust system

Fig. 97: Components to be checked 1 2

Exhaust gas turbocharger Exhaust manifold

3

Exhaust gas stub

Check components for damage.

Check components for leaks.

Check components for tight fit.

Connection points between device side exhaust piping and exhaust gas stub 3, see documentation from the device manufacturer.

Connection points between exhaust gas turbocharger 1 and device side intake pipe, see documentation from the device manufacturer.

If components are damaged: Do not start engine.

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

Replace damaged components, see repair instruction.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

83

Maintenance

Operator's manual

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.

copyright © Liebherr Machines Bulle SA 2020

84

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Engine oil system

Fig. 98: Ancillary support housing side components 1 2 3

Oil pan Oil cooler Cylinder head gasket

4 5 6

Cylinder head cover seal Oil supply line Oil return line

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

85

Maintenance

Operator's manual

Engine oil system

Fig. 99: Flywheel side components 1 2

Crankcase breather system Oil dipstick

3

Oil level switch

Check components for damage.

Check components for leaks.

Check components for tight fit.

Check oil loss at other components.

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

Replace damaged components, see repair instruction.

copyright © Liebherr Machines Bulle SA 2020

86

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Engine oil system

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

Damage to health and environmental damage possible.

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

Make sure that no lubricant gets into the environment.

Observe national and international guidelines for disposal.

Fig. 100: Checking the engine oil level 1 2

Oil filler cap Oil filler neck

3

Oil dipstick

Start engine.

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

Wait 5 minutes.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

87

Maintenance

Operator's manual

Engine oil system

Pull out oil dipstick 3.

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

Insert oil dipstick 3.

Pull out oil dipstick 3.

Fig. 101: Oil dipstick 1

Maximum (fill quantity: 40 l)

2

Minimum (fill quantity: 32 l)

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 oil.

Insert oil dipstick 3.

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.

Engine oil is available.

Engine oil specification (For more information see: 5.11.2 Engines oil for diesel engines with emission limit stage (EU) 2016/1628 stage V, page 139.)

Draining the engine oil Draining the engine oil at the oil pan 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.

copyright © Liebherr Machines Bulle SA 2020

88

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Engine oil system

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

Damage to health and environmental damage possible.

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

Make sure that no lubricant gets into the environment.

Observe national and international guidelines for disposal.

Fig. 102: Draining the engine oil 1 2

Oil drain valve Lid

3

Drain hose

Put a collection container under the oil pan.

Unscrew lid 2.

Place end of drain hose 3 in collection container.

Install drain hose 3 on oil drain valve 1.

Engine oil runs out.

Dispose of engine oil properly.

Remove drain hose 3.

Tighten lid 2.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

89

Maintenance

Operator's manual

Engine oil system

Draining the engine oil at the flywheel housing

Fig. 103: Draining the engine oil at the flywheel housing 1 2

Drain hose Drain valve

3

Lid

Put a collection container under the oil pan.

Unscrew lid 3.

Place end of drain hose 1 in collection container.

Install drain hose 1 on drain valve 2.

Engine oil runs out.

Dispose of engine oil properly.

Remove drain hose 1.

Tighten lid 3.

Replacing 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.

copyright © Liebherr Machines Bulle SA 2020

90

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Engine oil system

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

Damage to health and environmental damage possible.

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

Make sure that no lubricant gets into the environment.

Observe national and international guidelines for disposal.

Replace oil filter, see documentation from the device manufacturer.

Filling the engine oil

Fig. 104: Checking the engine oil level 1 2

Oil filler cap Oil filler neck

3

Oil dipstick

Remove oil filler cap 1.

If the entire oil has been drained: Fill 40 l of oil via the oil filler neck 2.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

91

Maintenance

Operator's manual

Engine oil system

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

Clean oil filler cap 1.

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

Start engine.

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

5.4.4 Replacing 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.

Removing the oil separator filter insert Make sure that the following prerequisites are met: An oil separator filter insert and sealing rings are ready.

NBU 30 grease (10285708) is available.

copyright © Liebherr Machines Bulle SA 2020

92

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Engine oil system

Fig. 105: Replacing the oil separator filter insert 1 2 3 4 5

M8 x 20 8.8 hex bolts Oil separator lid Clamp Hose O-ring

6 7 8 9 10

M6 x 50 8.8 cylinder screw Oil separator filter insert O-ring O-ring Drive shaft crankcase breather system

Clean oil separator lid 2 and surrounding area.

Release clamp 3.

Remove hose 4.

Unscrew hex bolts 1.

Remove oil separator lid 2.

Remove o-ring 5.

Unscrew cylinder screw 6.

Pull out the oil separator filter insert 7.

Dispose of the oil separator filter insert 7 in an environmentally friendly manner.

Remove o-ring 8.

Remove o-ring 9.

Dispose of the used o-rings in an environmentally friendly manner.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

93

Maintenance

Operator's manual

Engine oil system

Installing the oil separator filter insert

Fig. 106: Replacing the oil separator filter insert 1 2 3 4 5

M8 x 20 8.8 hex bolts Oil separator lid Clamp Hose O-ring

6 7 8 9 10

M6 x 50 8.8 cylinder screw Oil separator filter insert O-ring O-ring Drive shaft crankcase breather system

Replace the o-ring 8.

Replace the o-ring 9.

Lubricate the o-ring 8 with NBU 30 grease.

Lubricate the o-ring 9 with NBU 30 grease.

Thread the o-ring 8 onto the drive shaft crankcase breather system 10.

Thread the o-ring 9 onto the drive shaft crankcase breather system 10.

Replace the oil separator filter insert 7.

Insert the oil separator filter insert 7.

Tighten cylinder screws 6.

Lubricate the o-ring 5 with NBU 30 grease.

Insert o-ring 5 in groove of oil separator lid 2.

Install oil separator lid 2.

Place hose 4 on oil separator lid 2.

Tighten clamp 3.

Tighten hex bolts 1.

copyright © Liebherr Machines Bulle SA 2020

94

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Cylinder head

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

Fig. 107: 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.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

95

Maintenance

Operator's manual

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. 108 1

External hex bolt

2

Locking part

Unscrew the external hex bolt 1.

Remove the locking part 2.

Installing the turning device Graphic representation

Description

Required number

Identification number

Turning device

1

0524045

Tab. 19: Special tool

copyright © Liebherr Machines Bulle SA 2020

96

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Cylinder head

Fig. 110: Installing the turning device 1

Turning device

2

Flywheel housing opening

Install the turning device 1 on the flywheel housing opening 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. 20: Differences between ignition TDC and overlapping TDC

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

97

Maintenance

Operator's manual

Cylinder head

Fig. 111: Valve overlap

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

Valves of the cylinder set (ignition TDC)

1 5 3 6 2 4

overlap (overlapping TDC) 6 2 4 1 5 3 Tab. 21: Valves of the cylinder

copyright © Liebherr Machines Bulle SA 2020

98

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Cylinder head

Setting cylinder 1 to ignition TDC

Fig. 112: TDC marks: Ignition TDC for cylinder 1 1

TDC marking on the flywheel

2

Reference marking on flywheel housing

Turn crankshaft with turning device counterclockwise.

TDC marking on flywheel 1 and reference marking on flywheel housing 2 align.

Cylinder 1 is in ignition TDC position.

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

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

99

Maintenance

Operator's manual

Cylinder head

Fig. 113: M32 external hex 1

M32 external hex Attach tool with hexagon socket on M32 external hex 1.

Turn crankshaft clockwise.

TDC marking on flywheel 1 and reference marking on flywheel housing 2 align.

Cylinder 1 is in ignition TDC position.

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

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

Check if the cylinder rocker arm can be moved by hand. (For more information see: Setting table, page 98.)

The cylinder rocker arm can be moved by hand.

Cylinder is in ignition TDC position.

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

Checking and setting the valve clearance for the inlet valve and outlet valve Make sure that the following prerequisites are met: The engine has cooled down to the ambient temperature.

The cylinder head covers are removed.

The cylinder to be checked is at ignition TDC. (For more information see: Setting cylinder 2 to 6 to ignition TDC, page 100.)

Settings for valve clearance: (For more information see: 1.2.2 Valve clearance with ABS, page 36.)

copyright © Liebherr Machines Bulle SA 2020

100

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Cylinder head

Fig. 114: Check 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 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.

Tighten lock nut 3 according to tightening instruction.

Check the setting again.

Repeat the process for all cylinders.

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

Remove turning device.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

101

Maintenance

Operator's manual

Cylinder head

Tightening instruction for M10X1-6G6H lock nut Lubricant

-

Locking agent

-

Part contact surfaces

-

Screws

Reusable

Stage

Tightening torque

1.

45 Nm

Tab. 22: Tightening instruction

Checking and setting the valve clearance for the outlet valve with auxiliary brake system (ABS) Setting the valve clearance for the inlet valve: Make sure that the following prerequisites are met: The engine has cooled down to the ambient temperature.

The cylinder head covers are removed.

The cylinder to be checked is at ignition TDC. Settings for valve clearance on outlet valve with ABS: (For more information see: 1.2.2 Valve clearance with ABS, page 36.)

Fig. 116: Checking and setting the valve clearance on the ABS outlet valve 11445979_302 1 2 3 4 5

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

6 7

ABS lock nut Counterholder

8 9

Measuring point for feeler gauge on ABS ABS piston

copyright © Liebherr Machines Bulle SA 2020

102

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Cylinder head

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

Release the rocker arm lock nut 3.

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

Release the ABS lock nut 6.

Unscrew the ABS adjusting screw 5.

The ABS adjusting screw 5 disappears into the counterholder 7.

Press on the ABS valve bridge 1 with your hand.

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

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

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

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

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

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

ABS piston 9 goes to the limit stop.

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

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

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

Press on the ABS valve bridge 1 with your hand.

ABS piston 9 goes to the limit stop.

The push rod has play.

The valve clearance for the ABS adjusting screw is set.

Repeat the process for all cylinders.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

103

Maintenance

Operator's manual

Cylinder head

Removing the turning device

Fig. 117: Removing the turning device 1

Turning device

2

Flywheel housing opening

Remove the turning device 1 from the flywheel housing opening 2.

copyright © Liebherr Machines Bulle SA 2020

104

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Cylinder head

Installing the locking part

Fig. 118: Installing the locking part 1

External hex bolt

2

Locking part

Install the locking part 2.

Tighten the external hex bolt 1.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

105

Maintenance

Operator's manual

Cylinder head

Installing the cylinder head cover

Fig. 119: 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.

copyright © Liebherr Machines Bulle SA 2020

106

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Cylinder head

Tensioning instruction for M4 hex nut Lubricant

-

Locking agent

-

Part contact surfaces

-

Screws

-

Stage

Tightening torque

1.

1.8 Nm

Tab. 23: Tightening instruction 12977315_000 Tighten the hex nuts 7 according to the tensioning instruction.

Install the cylinder head cover 2.

Tighten the external hex bolts 1.

Tighten the external hex bolt 3.

Connect the electrical line to the electrical plug connection 4.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

107

Maintenance

Operator's manual

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. 121 1 2 3 4 5 6

Cooler coolant return Coolant pump Cooler coolant supply Cylinder head gasket Locking part Coolant ventilation

7 8 9 10 11 12

Expansion tank supply Cab heating/intarder supply (optional) Expansion tank return Oil cooler Immersion heater connection (optional) Cab heating return

copyright © Liebherr Machines Bulle SA 2020

108

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Cooling system

Check components for leaks.

Check components for damage.

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

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

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

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

Replace damaged components, see repair instruction.

5.6.2 Checking the coolant level 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 109.)

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. 122, page 110). copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

109

Maintenance

Operator's manual

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

Coolant fill quantity in liters

3

2

Measured concentration in vol. %

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 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 on the device, see documentation from the device manufacturer.

Draining the coolant on the engine Graphic representation

Description

Drain hose

Required number

Identification number

1

12690422

copyright © Liebherr Machines Bulle SA 2020

110

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Cooling system

Graphic representation

Description

Drain hose 90°

Required number

Identification number

1

12690423

Tab. 24: 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.

Fig. 125 1 2

Lid Drain valve

3

Drain hose

Remove lid from device side coolant expansion tank.

Remove lid 1. copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

111

Maintenance

Operator's manual

Cooling system

Connect drain hose 3 to the drain valve 2.

Coolant runs out.

When the coolant has drained completely: Remove drain hose 3.

Install lid 1.

Install lid of device side coolant expansion tank.

Filling the coolant Fill the coolant via the device side filler neck. (For more information see: Correcting the concentration of the antifreeze agent, page 109.)

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 64.)

Let the engine cool down.

Check coolant level. (For more information see: 5.6.2 Checking the coolant level, page 109.)

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

copyright © Liebherr Machines Bulle SA 2020

112

D956 A7-05 / LHB / 2019060001

Operator's manual

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. 126 1 2 3

Fuel fine filter console Fuel high pressure pump Injection pipe

4 5 6

Fuel return line Rail Fuel low pressure line

Check components for damage.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

113

Maintenance

Operator's manual

Fuel system

Check components for proper fastening.

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

If components are damaged: Do not start engine.

Replace defective components, see repair instruction

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

For procedure to check the water separator on the fuel prefilter, see documentation from the device manufacturer.

If there is water in the water separator: Drain the water. (For more information see: 5.7.3 Draining the water from the water separator in the fuel prefilter, page 114.)

5.7.3 Draining the water from the water separator in the fuel prefilter Note The fuel prefilter with water separator is not mounted directly on 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 liquid is available.

For procedure to drain the water from the water separator in the fuel prefilter, see documentation from the device manufacturer.

5.7.4 Draining water and sediment from the fuel tank Make sure that the following prerequisites are met: A collection container for escaping liquid is available.

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

5.7.5 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.

copyright © Liebherr Machines Bulle SA 2020

114

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Fuel system

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.

5.7.6 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 150.)

Pressure below 10 bar

5.7.7 Replacing 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.

Removing the fuel fine filter If the engine is running: Turn off engine.

Wait 20 minutes.

Check pressure reduction with diagnostics software. (variables: 6996 - Fuel Pressure High 1/ 6997 - Fuel Pressure High 2) (For more information see: 7.1.3 Diagnostic tools, page 150.)

Replace fuel fine filter, see documentation from the device manufacturer.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

115

Maintenance

Operator's manual

Fuel system

5.7.8 Ventilating the fuel system

3

1

2

4

5

6

Fig. 127: 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.

copyright © Liebherr Machines Bulle SA 2020

116

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Air filter

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

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

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

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

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

117

Maintenance

Operator's manual

Electrical system

5.9 Electrical system 5.9.1 Checking the batteries Check components for contamination, see documentation from the device manufacturer.

Check components for mechanical damage, 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. 128: 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 engine.

Replace bearings, see repair instruction.

copyright © Liebherr Machines Bulle SA 2020

118

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Electrical system

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

Damage to plug connections.

Leave plug connections plugged in during the visual inspection.

Fig. 129: Components to be checked 1 2

Speed sensor Temperature and pressure sensor

3 4

Temperature sensor Pressure sensor

Check components for tight fit.

Check components for damage.

Check components for abrasion-free laying.

Check components for proper fastening.

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

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

Replace defective components, see repair instruction.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

119

Maintenance

Operator's manual

Electrical system

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

Fig. 130: Checking the heating flange 1 2 3 4

Heating flange Positive pole Seal Heating flange flow direction

5 6 7

Charge air pipe External hex bolt External hex bolt

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 heating flange 1.

Release external hex bolt 6.

Release external hex bolt 7.

Remove charge air pipe 5.

Remove seal 3.

Remove heating flange 1.

Remove seal 3.

copyright © Liebherr Machines Bulle SA 2020

120

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Electrical system

Tightening instruction for M6 external hex bolts Lubricant

-

Locking agent

-

Part contact surfaces

-

Screws

Reusable

Stage

Tightening torque

1.

11 ±1 Nm

Tab. 25: Tightening instruction Tighten external hex bolts in the heating flange according to tightening instruction.

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

Note The inside of the screw hole on the heating flange can be used as a ground connection.

Measure the resistance.

If the resistance at 20 °C falls below 230 ±23 m : Replace heating flange. (For more information see: Checking the heating flange for sooting, page 122.)

Replace seals 3.

Install heating flange 1.

Tighten external hex bolt 6.

Tighten external hex bolt 7.

Connect electrical connection cable to heating flange 1.

Connect negative cable to battery.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

121

Maintenance

Operator's manual

Electrical system

Checking the heating flange for sooting

Fig. 132: Checking the heating flange 1 2 3 4

Heating flange Positive pole Seal Heating flange flow direction

5 6 7

Charge air pipe External hex bolt External hex bolt

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 heating flange 1.

Release external hex bolt 6.

Release external hex bolt 7.

Remove charge air pipe 5.

Check heating flange 1 for sooting.

If the heating flange 1 is sooted: Remove heating flange 1 Clean heating flange 1 with brake cleaner.

Remove brake cleaner residues from heating flange 1.

Replace seals 3.

Install heating flange 1.

Tighten external hex bolt 6.

Tighten external hex bolt 7.

copyright © Liebherr Machines Bulle SA 2020

122

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Electrical system

Connect electrical connection cable to heating flange 1.

Connect negative cable to battery.

5.9.6 Replacing the heating flange

Fig. 133: Checking the heating flange 1 2 3 4

Heating flange Positive pole Seal Heating flange flow direction

5 6 7

Charge air pipe External hex bolt External hex bolt

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

Disconnect the negative cable from the battery.

Disconnect electrical connection cable from positive pole 2.

Release external hex bolt 6.

Release external hex bolt 7.

Remove charge air pipe 5.

Replace seals 3.

Remove heating flange 1.

Install new heating flange 1.

Tighten external hex bolt 6.

Tighten external hex bolt 7.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

123

Maintenance

Operator's manual

Electrical system

Connect electrical connection cable to heating flange 1.

Connect negative cable to battery.

copyright © Liebherr Machines Bulle SA 2020

124

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Exhaust aftertreatment system

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

Serious poisoning possible.

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

WARNING Hot components on the engine!

Serious burns possible.

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

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

125

Maintenance

Operator's manual

Exhaust aftertreatment system

Fig. 134: Components to be checked 1 2 3 4

Profile clamp (2x) Sensor connection (13x) Hinge bracket (2x) Reduction agent injector (1x)

5 6 7

Bracket clip (2x) Profile clamp (3x) Profile clamp (2x)

Check components for leaks.

Check components for tight fit.

Check components for damage.

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

Tighten loose components.

Replace damaged components, see repair instruction.

copyright © Liebherr Machines Bulle SA 2020

126

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Exhaust aftertreatment system

5.10.3 Check components 5.10.4 SCRFilter (single-flow) WARNING Production of ammonia gas when heating above 100 °C from reducing agent deposits.

Serious poisoning possible.

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

WARNING Hot components on the engine!

Serious burns possible.

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

7

7 5 1

1

5

7

1 6

7 7 4

2

2

4

7 7 3 7 8 3 Fig. 135: Tightening torques 1 2

Profile clamp (3x) Profile clamp (2x)

5 6

Bracket clip (2x) Reducing agent injector (1x)

See next page for continuation of the image legend

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

127

Maintenance

Operator's manual

Exhaust aftertreatment system

3

Profile clamp (2x)

7

4

Hinge bracket (2x)

8

Temperature sensor/pressure sensor/ differential pressure line/screw fitting (13x) NOx sensor/NH3 sensor (1x)

Number Part

Tightening torque

1

Profile clamp 1

23 ±2 Nm

2

Profile clamp 2

18 +2/ -1 Nm

3

Profile clamp 3

23 ±2 Nm

4

Hinge bracket 4

21 ±1 Nm

5

Bracket clip 5

23 ±2 Nm

6

Reduction agent injector 6

5 ±0.5 Nm

7

Temperature sensor/pressure sensor/differential pressure line/ screw fitting 7

35 +5/ -0 Nm

8

NOx sensor/NH3 sensor 8

50 ±10 Nm

Tab. 26: Tightening torques Check component for tight fit.

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

5.10.5 Cleaning the SCR filter module Replacing the filter module The filter module replacement is based on an exchange principle. That means that during an upcoming maintenance interval, a cleaned replacement (AT) filter module is ordered and installed.

The filter module replacement is monitored by a diagnostics system. 5000h after the last filter module replacement, a warning appears on the device display that the filter module must be replaced. If this is not performed, after 6000h, the AWL lamp or MIL lamp appears or an error is permanently displayed, and a power limitation automatically takes place.

5000h since the last filter module replacement

6000h since the last filter module replacement Permanent error (P13E2)

Warning (P242F) is shown in the device display when the ignition is switched on

AWL lamp

lights up.

Filter module lamp up.

lights

Low power limitation Tab. 27: Monitoring of the filter module replacement maintenance interval

copyright © Liebherr Machines Bulle SA 2020

128

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Exhaust aftertreatment system

Ordering the AT filter module NOTICE Improper maintenance Damage to the filter element The filter module requires an adapted / new cleaning technology and procedure for the periodic ash cleaning.

The cleaning technology for Stage IIIB / Tier 4i and retrofit DPF may not be used under any circumstances!

The procedure applied for the conventional DPF (CRT® or SCRT®) can lead to irreparable damage and destruction of the filter element for the filter module.

Order a new AT filter module via the spare parts catalog.

Unpack the new AT filter module.

Keep the packing for the AT filter module.

Removing the filter module (single-flow) Removing the differential pressure line

Fig. 136: Removing the differential pressure line 1 2

Pipeline Spring band clamp

3

Hose line

Release spring band clamp 2.

Pull hose line 3 out of pipeline 1.

Pull spring band clamp 2 out of hose line 3 Check hose line 3 for damage.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

129

Maintenance

Operator's manual

Exhaust aftertreatment system

If the hose line 3 is damaged: Replace the hose line 3 with a new part.

Note Replace the spring band clamp 2 with a new part each time it is released.

Variant 1: Remove inlet module in order to replace the filter module WARNING Production of ammonia gas when heating above 100 °C from reducing agent deposits.

Serious poisoning possible.

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

WARNING Hot components on the engine!

Serious burns possible.

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

Fig. 137: Removing the filter module 1 2 3 4 5 6

Inlet module Hinge bracket Profile clamp Seal Profile clamp Mixing pipe

7 8 9 10 11 12

Seal Filter module Profile clamp Seal Hinge bracket SCR outlet module

Secure the filter module 8 against falling with a securing element (wooden block, sling, support). copyright © Liebherr Machines Bulle SA 2020

130

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Exhaust aftertreatment system

Release the profile clamp 3 and slide it on the inlet module 1.

Release the profile clamp 5 and slide it on the filter module 8.

Release the hinge bracket 2.

Push the inlet module 1 back at least 40 mm.

Release the profile clamp 9 and slide it on the SCR outlet module 12.

Release filter module 8.

Remove filter module 8.

Note While the filter module 2 is not installed, protect all openings against dirt and moisture.

Remove seal 4.

Remove seal 7.

Remove seal 10.

Note Replace the seal and profile clamp with new parts each time they are released.

Protect all openings against dirt and moisture.

Variant 2: Removing the outlet module WARNING Production of ammonia gas when heating above 100 °C from reducing agent deposits.

Serious poisoning possible.

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

WARNING Hot components on the engine!

Serious burns possible.

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

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

131

Maintenance

Operator's manual

Exhaust aftertreatment system

Fig. 138: Removing the filter module 1 2 3 4 5 6

Inlet module Hinge bracket Profile clamp Seal Profile clamp Mixing pipe

7 8 9 10 11 12

Seal Filter module Profile clamp Seal Hinge bracket SCR outlet module

Secure the filter module 8 against falling with a securing element (wooden block, sling, support).

Release the profile clamp 9 and slide it on the SCR outlet module 12.

Release the profile clamp 5 and slide it on the filter module 8.

Release the hinge bracket 11.

Push the SCR outlet module 12 back at least 40 mm.

Release filter module 8.

Remove filter module 8.

Remove seal 7.

Remove seal 10.

Note Replace the seal and profile clamp with new parts each time they are released.

Protect all openings against dirt and moisture.

Packing the filter module for transport Note Have the filter module cleaned by authorized Liebherr service centers.

copyright © Liebherr Machines Bulle SA 2020

132

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Exhaust aftertreatment system

Pack the filter module to be cleaned in the packing of the new filter module.

Send the filter module to an authorized Liebherr service center for cleaning.

Installing the filter module (single-flow) Variant 1: Installing the inlet module

Fig. 139: Installing the filter module 1 2 3 4 5 6

Inlet module Hinge bracket Profile clamp Seal Profile clamp Mixing pipe

7 8 9 10 11 12

Seal Filter module Profile clamp Seal Hinge bracket Outlet module

WARNING Production of ammonia gas when heating above 100 °C from reducing agent deposits.

Serious poisoning possible.

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

WARNING Hot components on the engine!

Serious burns possible.

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

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

133

Maintenance

Operator's manual

Exhaust aftertreatment system

Note Replace the seal and profile clamp with new parts.

Clean sealing surface.

Install new seal 4.

Install new seal 7.

Install new seal 10.

Slide new profile clamp 5 on the filter module.

Slide new profile clamp 9 on the filter module.

Install new filter module 8.

NOTICE Damage to the seal!

Escaping exhaust Do not turn the filter module 8 in installed condition.

Secure the filter module 8 against falling with a securing element (wooden block, sling, support).

Slide new profile clamp 3 on the inlet module 1.

Slide the inlet module 1 in the direction of the filter module 8.

Tighten the profile clamp 3 according to specifications. (For more information see: 5.10.4 SCRFilter (single-flow), page 127.)

Tighten profile clamp 5 according to specifications. (For more information see: 5.10.4 SCRFilter (single-flow), page 127.)

Tighten profile clamp 9 according to specifications. (For more information see: 5.10.4 SCRFilter (single-flow), page 127.)

NOTICE Leaks on the exhaust emission reduction assembly!

Escaping exhaust During tightening, distribute the tension in the profile clamps with gentle taps of a rubber mallet.

Tighten profile clamp 3 according to specifications. (For more information see: 5.10.4 SCRFilter (single-flow), page 127.)

Tighten profile clamp 5 according to specifications. (For more information see: 5.10.4 SCRFilter (single-flow), page 127.)

Tighten profile clamp 9 according to specifications. (For more information see: 5.10.4 SCRFilter (single-flow), page 127.)

Tighten hinge bracket 2 according to specifications. (For more information see: 5.10.4 SCRFilter (single-flow), page 127.)

Release filter module 8.

copyright © Liebherr Machines Bulle SA 2020

134

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Exhaust aftertreatment system

Variant 2: Installing the outlet module

Fig. 140: Installing the filter module 1 2 3 4 5 6

Inlet module Hinge bracket Profile clamp Seal Profile clamp Mixing pipe

7 8 9 10 11 12

Seal Filter module Profile clamp Seal Hinge bracket Outlet module

WARNING Production of ammonia gas when heating above 100 °C from reducing agent deposits.

Serious poisoning possible.

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

WARNING Hot components on the engine!

Serious burns possible.

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

Note Replace the seal and profile clamp with new parts.

Clean sealing surfaces Install seal 7.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

135

Maintenance

Operator's manual

Exhaust aftertreatment system

Install seal 10.

Slide the profile clamp 9 on the filter module.

Slide the profile clamp 5 on the filter module.

Install filter module 8.

Secure the filter module 8 against falling with a securing element (wooden block, sling, support).

Slide the outlet module 12 in the direction of the filter module 8.

Tighten the profile clamp 9 according to specifications. (For more information see: 5.10.4 SCRFilter (single-flow), page 127.)

Tighten profile clamp 5 according to specifications. (For more information see: 5.10.4 SCRFilter (single-flow), page 127.)

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.

Tighten profile clamp 9 according to specifications. (For more information see: 5.10.4 SCRFilter (single-flow), page 127.)

Tighten profile clamp 5 according to specifications. (For more information see: 5.10.4 SCRFilter (single-flow), page 127.)

Tighten hinge bracket 11 according to specifications. (For more information see: 5.10.4 SCRFilter (single-flow), page 127.)

Release filter module 8.

copyright © Liebherr Machines Bulle SA 2020

136

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Exhaust aftertreatment system

Installing the differential pressure line

Fig. 141: Removing the differential pressure line 1 2

Pipeline Spring band clamp

3

Hose line

Slide new spring band clamp 2 on the hose line 3.

Push hose line 3 onto pipeline 1.

Fasten spring band clamp 2.

After replacing the filter module After replacing the filter module, a reset of the maintenance interval in the engine control unit is required. Depending on the machine type, this reset can occur either through the machine itself or via the engine service tool, see documentation from the device manufacturer.

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.

Observe the accompanying documents in the packing of the new filter module.

Warm up the engine.

Coolant temperature > 60 °C Turn off the diesel engine.

Check tightening torque of the profile clamps according to the tightening instruction. (For more information see: 5.10.4 SCRFilter (single-flow), page 127.)

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

137

Maintenance

Operator's manual

Exhaust aftertreatment system

Check the tightening torque of the hinge brackets according to the tightening instruction. (For more information see: 5.10.4 SCRFilter (single-flow), page 127.)

Check the exhaust aftertreatment assembly for leaks. (For more information see: 5.10.2 SCRFilter (single-flow), page 125.)

copyright © Liebherr Machines Bulle SA 2020

138

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Lubricants and operating fluids

5.11 Lubricants and operating fluids 5.11.1 Fill quantities Name

Quantity

Engine oil

46 l (1.5 l per filter)

Coolant (engine) 24 l Reduction agent See documentation from the device manufacturer.

Tab. 28: Fill quantities (reference values)

5.11.2 Engines oil for diesel engines with emission limit stage (EU) 2016/1628 stage V 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 10

(EU) 2016/1628 stage V 100% (standard interval according to maintenance schedule)

Liebherr recommends the use of the following products

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

Lubricating oil specification

LH-00-ENG LA

Tab. 29: 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.

Sulfur content in fuel in ppm

(EU) 2016/1628 stage V

10

50%

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

139

Maintenance

Operator's manual

Lubricants and operating fluids

Sulfur content in fuel in ppm

(EU) 2016/1628 stage V

Lubricating oil specification

LH-00-ENG LA

Tab. 30: Engine oil change intervals when using non-Liebherr products

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

Avoid combining different products.

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

Anticorrosive antifreeze agent Liebherr recommendation Type

Name

Premix ) Liebherr Antifreeze OS Mix A

Tab. 31: 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. 32: 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. 33: Minimum requirements for the quality

copyright © Liebherr Machines Bulle SA 2020

140

D956 A7-05 / LHB / 2019060001

Operator's manual

Maintenance Lubricants and operating fluids

5.11.4 Fuel for diesel engines with emission limit stage (EU) 2016/1628 stage V Minimum requirement for the quality Approved diesel fuels according to DIN EN 590 and ASTM D975 1-D S15/2-D S15

(EU) 2016/1628 stage V

Maximum sulfur content in the fuel

10 ppm

Lubricity at 60 °C (HFRR)

460 m

Fuel purity for tank filling according to ISO 4406:

18/17/14

Minimum cetane number

45

Maximum fatty acid methyl ester (FAME) content

7 vol. %

Tab. 34: Minimum requirement for diesel fuels Specification LH-00-FUEL Tab. 35: Minimum requirement for the quality

Reduction agent Approved reduction agent: – Reduction agent standardized according to ISO 22241 Specification LH-00-UREA Tab. 36: Minimum requirement for the quality for better results Designations: – AdBlue® in Europe – DEF (Diesel exhaust fluid) in the USA – AUS 32 (aqueous urea solution)

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

141

Maintenance

Operator's manual

Lubricants and operating fluids

copyright © Liebherr Machines Bulle SA 2020

142

D956 A7-05 / LHB / 2019060001

6 Malfunctions

See Faults - Cause - Remedy table for engine problems and corrective measures. (For more information see: 6.1 Faults - Cause - Remedy, page 143.)

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 150.)

6.1 Faults - Cause - Remedy Malfunction / error

Cause

Remedy

Starter does not crank.

Main fuse defective

Replace fuse.

Starter does not crank.

Battery connections loose or corroded

Clean and tighten loose connections.

Clean contacts.

Starter does not crank.

Battery voltage too low

Charge or replace battery.

Starter does not crank.

Starter circuit interrupted

Contact Liebherr customer service.

Starter does not crank.

Contacts corroded

Clean contacts.

Starter does not crank.

Starter defective

Contact Liebherr customer service.

Starter cranks slowly.

Battery voltage too low

Charge or replace battery.

Starter cranks slowly.

Battery connections loose or corroded

Clean and tighten loose connections.

Starter cranks slowly.

Outside temperature too low

Follow measures for winter operation.

Starter cranks slowly.

Engine under load

Disconnect the unit from the auxiliary output.

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

Engine stops immediately after starting.

Fuel tank empty

Engine stops immediately after starting.

Fuel fine filter clogged

Refuel.

Ventilate the fuel system.

Replace the fuel fine filter.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

143

Malfunctions

Operator's manual

Faults - Cause - Remedy

Malfunction / error

Cause

Remedy

Engine stops immediately after starting.

Fuel prefilter clogged

Replace the fuel prefilter.

Engine stops immediately after starting.

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

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

Ventilate the fuel system.

Engine stops immediately after starting.

Fuel not cold-resistant

Clean the fuel prefilter.

Replace the fuel fine filter.

Use winter fuel.

Engine stops immediately after starting.

Outside temperature too low

Follow measures for winter operation.

Engine stops immediately after starting.

Heating flange defective (at cold temperatures)

Check heating flange, replace if necessary.

Engine stops immediately after starting.

Exhaust gas system dirty

Clean exhaust gas system.

Engine stops immediately after starting.

Engine brake flap closed

Check engine brake flap control.

Engine starts poorly.

Leak or too low pressure in the fuel low pressure circuit

Contact Liebherr customer service.

Perform leak test (visual inspection).

Contact Liebherr customer service.

Engine starts poorly.

Engine compression too low

Contact Liebherr customer service.

Engine starts poorly.

Heating flange defective (at cold temperatures)

Check heating flange, replace if necessary.

Engine starts poorly.

Fault of the electronics

Contact Liebherr customer service.

Engine starts poorly.

Rail pressure too low

Inspect rail for leaks.

Engine starts poorly.

Air in fuel system

Ventilate the fuel system.

Engine starts poorly.

Air filter clogged

Check air filter for contamination.

Engine starts poorly.

Inferior fuel quality

Only use fuel recommended by Liebherr.

Engine starts poorly.

Injector defective

Contact Liebherr customer service.

Engine starts poorly.

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

For engines without hydraulic tappets: Check valve clearance.

If necessary, set valve clearance.

For engines with hydraulic tappets: Contact Liebherr customer service.

Engine turns off inadvertently.

Voltage supply interrupted

Contact Liebherr customer service.

copyright © Liebherr Machines Bulle SA 2020

144

D956 A7-05 / LHB / 2019060001

Operator's manual

Malfunctions Faults - Cause - Remedy

Malfunction / error

Cause

Engine turns off inadvertently.

Leak or too low pressure in the fuel low pressure circuit

Remedy Perform leak test (visual inspection).

Have checked by Liebherr customer service.

Engine turns off inadvertently.

Fault of the electronics

Contact Liebherr customer service.

Engine turns off inadvertently.

Fuel supply not ensured

Check fuel system.

Power reduction of the engine

Fuel system defective

Perform visual inspection.

Replace filter.

Power reduction of the engine

Charging pressure too low

Check clamps, seals, hoses and air filter.

Power reduction of the engine

Charge air temperature too high

Check charge air cooler, fan and ambient temperature.

Power reduction of the engine

Coolant temperature too high

Check cooler for contamination.

Check fan.

Check thermostat.

Check coolant level.

Power reduction of the engine

Fuel temperature too high

Contact Liebherr customer service.

Power reduction of the engine

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

Power reduction of the engine

Injectors stick or do not spray.

Contact Liebherr customer service.

Power reduction of the engine

Engine compression too low

Contact Liebherr customer service.

Power reduction of the engine

Fault of the electronics

Read error memory of the engine control unit.

Power reduction of the engine

Exhaust aftertreatment system clogged

Contact Liebherr customer service.

Power reduction of the engine

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

For engines without hydraulic tappets: Check valve clearance.

If necessary, set valve clearance.

For engines with hydraulic tappets: Contact Liebherr customer service.

Power reduction of the engine

Too little reducing agent in reducing agent tank

Fill up reducing agent.

Insufficient engine brake power

Engine brake flap without function

Check engine brake flap for function and damage.

No defect, engine power automatically reduced.

Contact Liebherr customer service.

Insufficient engine brake power

Fault of the electronics

Contact Liebherr customer service.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

145

Malfunctions

Operator's manual

Faults - Cause - Remedy

Malfunction / error

Cause

Remedy

Hot engine (according to coolant temperature display).

Too little coolant

Refill.

Hot engine (according to coolant temperature display).

Cooler dirty inside or calcified, cooler dirty outside

Clean cooler.

Hot engine (according to coolant temperature display).

Thermostat defective

Check thermostat.

Hot engine (according to coolant temperature display).

Coolant temperature sensor defective

Decalcify cooler.

If necessary, replace thermostat.

Check coolant temperature sensor.

If necessary, replace coolant temperature sensor.

Hot engine (according to coolant temperature display).

Fan speed too low (only hydrostatic fan drive)

Check fan drive.

Hot engine (according to coolant temperature display).

Coolant pump defective

Replace coolant pump.

Hot engine (according to coolant temperature display).

V-ribbed belt tension insufficient

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

Charging current indicator light illuminates when engine is running.

V-ribbed belt torn

Replace V-ribbed belt.

Charging current indicator light illuminates when engine is running.

Cable connections loose or disconnected

Fasten or replace cable.

Charging current indicator light illuminates when engine is running.

Alternator, rectifier or controller defective

Contact Liebherr customer service.

Charging current indicator light illuminates when engine is running.

Open test circuit

Contact Liebherr customer service.

Engine smokes black.

Exhaust aftertreatment system defective

Contact Liebherr customer service.

Engine smokes black.

Injection system defective

Contact Liebherr customer service.

Engine smokes black.

Charge air pressure sensor defective

Replace charge air pressure sensor.

Exhaust gases are blue.

Oil level in engine too high

Correct oil level.

Exhaust gases are blue.

Engine oil burns in combustion chambers.

Contact Liebherr customer service.

Exhaust gases are blue.

Compressor-side seal on the exhaust gas turbocharger defective

Contact Liebherr customer service.

Exhaust gases are blue.

Exhaust gas-side seal on the exhaust gas turbocharger defective

Contact Liebherr customer service.

Exhaust gases are blue.

Crankcase breather system defective

Check, replace if necessary.

Exhaust gases are blue.

Piston rings defective

Contact Liebherr customer service.

Exhaust gases are blue.

Valve stem seals defective

Contact Liebherr customer service.

If necessary, replace fan drive.

copyright © Liebherr Machines Bulle SA 2020

146

D956 A7-05 / LHB / 2019060001

Operator's manual

Malfunctions Faults - Cause - Remedy

Malfunction / error

Cause

Remedy

Exhaust gases are white.

Injection delayed

Contact Liebherr customer service.

Exhaust gases are white.

Heating flange defective (temperature < -10 °C)

Check heating flange. If necessary, replace heating flange.

Exhaust gases are white.

Coolant in combustion chamber

Contact Liebherr customer service.

Engine rattles.

Combustion faults

Contact Liebherr customer service.

Engine knocks.

Injection nozzles damaged or coked

Contact Liebherr customer service.

Engine knocks.

Bearing damage

Contact Liebherr customer service.

Engine knocks.

Piston rings worn, piston rings broken, piston scuffed

Contact Liebherr customer service.

Abnormal noises

Leaks on suction lines and exhaust pipes cause whistling noises.

Eliminate leak. If necessary, replace seal.

Abnormal noises

Foreign object in compressor or turbine

Contact Liebherr customer service.

Abnormal noises

Turbine wheel or compressor wheel rubbing against housing

Contact Liebherr customer service.

Abnormal noises

Seized bearings on rotating parts

Contact Liebherr customer service.

Lubricating oil pressure too low

Oil level in the oil pan too low

Correct oil level.

Lubricating oil pressure too low

Engine oil too thin

Drain oil.

Fill the oil.

Determine cause of the oil dilution and rectify.

Lubricating oil pressure too low

Oil pressure sensor defective

Check engine oil system.

Replace damaged oil pressure sensor.

Lubricating oil pressure too low

End control valve defective

Contact Liebherr customer service.

Lubricating oil pressure too low

End control valve dirty

Contact Liebherr customer service.

Lubricating oil pressure too low

Bearing play due to wear too great or bearing damage

Contact Liebherr customer service.

Lubricating oil pressure too low

Oil pump defective

Check oil pump.

Replace oil pump, if necessary.

Lubricating oil pressure too low

Oil filter clogged

Replace oil filter.

Lubricating oil pressure too low

Oil pressure regulating valve defective

Contact Liebherr customer service.

Engine oil in cooling system

Oil cooler or oil cooler plate is leaking

Contact Liebherr customer service.

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

147

Malfunctions

Operator's manual

Faults - Cause - Remedy

Malfunction / error

Cause

Remedy

Coolant in engine oil

O-rings on cylinder liners are leaking

Contact Liebherr customer service.

Coolant in engine oil

Oil cooler or oil cooler plate is leaking

Contact Liebherr customer service.

copyright © Liebherr Machines Bulle SA 2020

148

D956 A7-05 / LHB / 2019060001

7 Tools and devices

7.1 Tools 7.1.1 Special tool Graphic representation

Description

Required number

Identification number

Turning device

1

0524045

M16x180 assembly pin (viscous damper)

2

0528470

Tab. 37: Special tool

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

Locking agent Designation Identification number Quantity Loctite 243

811205708

50 ml

Tab. 38: Locking agent Sealant Designation Identification number Quantity Loctite 5910 10354595

300 ml

Tab. 39: Sealant Lubricants Designation

Identification number Quantity

NBU 30 grease 10285708

1 kg

Motorex 14

850 g

10002552

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

149

Tools and devices

Operator's manual

Tools

Lubricants Altemp QNB 50 10490569

80 g

Tab. 40: Lubricants

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

copyright © Liebherr Machines Bulle SA 2020

150

D956 A7-05 / LHB / 2019060001

Operator's manual

Tools and devices Devices

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

Will lead to death or serious injuries due to crushing.

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

Observe maximum weight for lifting points.

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

Use a Liebherr lifting traverse. (For more information see: 7.2.1 Lifting traverse with three-pointraising (basic version), page 151.)

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. 144: 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

D956 A7-05 / LHB / 2019060001

151

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

Chain suspension T-slide piece Attachment point sticker(see: fig. 146, page 153)

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

152

D956 A7-05 / LHB / 2019060001

Operator's manual

Tools and devices Devices

Fig. 146: Attachment point sticker

7.2.2 Lifting traverse with two-point-raising

Fig. 147: Lifting traverse with two-point-raising 1 2

I-slide piece I-reception tube

3

Chain suspension

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

153

Tools and devices

Operator's manual

Devices

7.2.3 Engine assembly stand

Fig. 148: 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. 41: Technical data

copyright © Liebherr Machines Bulle SA 2020

154

D956 A7-05 / LHB / 2019060001

Operator's manual

Tools and devices Devices

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

Risk of injury or death.

Observe maximum weight for lifting points.

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

Use Liebherr lifting traverse.

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

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.

Tightening instruction for hex bolt Lubricant

-

Locking agent

-

Part contact surfaces

-

Screws

Reusable

Stage

Tightening torque

1.

Standard torque

Tightening sequence

Tab. 42: Tightening instruction Tightening instruction for hex bolt Lubricant

-

Locking agent

-

Part contact surfaces

-

Screws

Reusable

Stage

Tightening torque

1.

35 Nm

2.

70 ±10.5 Nm

Tightening sequence

Tab. 43: Ref. 12869202_100

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

155

Tools and devices

Operator's manual

Devices

copyright © Liebherr Machines Bulle SA 2020

156

D956 A7-05 / LHB / 2019060001

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

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

157

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. 44: 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. 45: 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

copyright © Liebherr Machines Bulle SA 2020

158

D956 A7-05 / LHB / 2019060001

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. 46: 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. 47: 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:

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

159

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. 48: Tightening torques for locking screws and banjo bolts

8.1.3 Standard torques for metric flange connections

Fig. 151: Overview of flange connections

copyright © Liebherr Machines Bulle SA 2020

160

D956 A7-05 / LHB / 2019060001

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. 49: 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. 50: Metric screw connection series L (light), part 2

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

161

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. 51: 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. 52: 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

copyright © Liebherr Machines Bulle SA 2020

162

D956 A7-05 / LHB / 2019060001

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. 53: 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. 54: 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

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

163

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. 55: 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. 56: 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. 57: Metric thread unit series L (up to 500 bar/7252 Psi) for aluminum Standard torques for cutting ring screw connections

copyright © Liebherr Machines Bulle SA 2020

164

D956 A7-05 / LHB / 2019060001

Operator's manual

Appendix Tightening torques

Fig. 152: 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. 58: 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. 153: Triple lock flange connections

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

165

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. 59: 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. 154: 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

166

D956 A7-05 / LHB / 2019060001

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. 60: Standard torques for VSTI screw plugs

copyright © Liebherr Machines Bulle SA 2020

D956 A7-05 / LHB / 2019060001

167

Appendix

Operator's manual

Tightening torques

copyright © Liebherr Machines Bulle SA 2020

168

D956 A7-05 / LHB / 2019060001