Liebherr Diesel engineD976 A7-04 D976 A7-05 Operating Manual

Operator's manual Diesel engine D976 A7-04 / D976 A7-05 From serial number 2019 06 0001

en

Document ID Order number: Issued: Version: Author:

ORIGINAL OPERATOR'S MANUAL 12948519 29.05.2019 00 LMB / Department DC2

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

Diesel engine D976 A7-04 / D976 A7-05 2019 06 0001

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

Change history

Version From serial number Changes included 00

2019 06 0001

Issue

Document newly created 05/29/2019[

copyright © Liebherr-Components Colmar SAS 2019

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Operator's manual

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Preface

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

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

Only use clean and undamaged tools. Damaged tools may not be continued to be used; replace them in a timely manner. Cleanliness and order contribute to safety at the workplace.

Clean the diesel engine, and here 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 tensioning instructions are specified, screwed assemblies are to be tightened according to the standard torques; these are included in the chapter “Appendix”.

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 these operating instructions, e.g. identification numbers, thread sizes, dimensions, etc., are only informational. Spare part orders may only be carried out by means of the spare parts catalog pertaining to the scope of delivery.

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

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

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Preface

Operator's manual

About the document

Usage instructions Some images in these operating instructions 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 these operating instructions.

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 operating instructions.

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Operator's manual

Preface Graphic symbols in these instructions

Graphic symbols in these instructions Symbol

Meaning Note Identifies useful information and tips.

Prerequisite Identifies conditions for the following action steps.

Call to action Identifies action steps.

Result Identifies results of one or more action steps.

–

Itemization Identifies individual points of a list.

Symbols

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Preface

Operator's manual

Changes, conditions, copyright:

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

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

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Contents

1

Product description

13

1.1

Technical description

13

1.1.1

Design

13

1.1.2

Exhaust aftertreatment system SCRonly

15

1.1.3

Engine type itemization

19

1.1.4

Company nameplate

20

1.1.5

Cylinder designation, direction of rotation

22

1.1.6

Engine control unit type plate

22

1.1.7

Exhaust aftertreatment system type plate

23

1.2

2

Technical data

26

1.2.1

Diesel engine D976 A7-04 / D976 A7-05

26

1.2.2

Coolant thermostat

26

Safety

27

2.1

Labeling of warnings

27

2.2

Additional labels

27

2.3

Target group

28

2.4

Intended use

28

2.5

Foreseeable misuse

28

2.6

General safety instructions

29

2.7

Preventing personal injuries

31

2.7.1

Bruises

31

2.7.2

Burns and scalds

31

2.7.3

Fires and explosions

31

2.7.4

Poisoning

31

2.7.5

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

32

2.7.6

Electrical energy

32

2.7.7

Danger due to noise

32

2.8

Personal protective equipment

32

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Contents

Operator's manual

2.9

3

5

33

2.9.1

Safety instructions

33

2.9.2

Operating areas

34

2.9.3

Maintenance areas

34

2.9.4

Secure and release the diesel engine against accidental starting

35

2.9.5

Emergency stop

36

2.10 Signage

36

2.11 Prevent material damages

37

Transport and storage

39

3.1

Dimensions and weights

39

3.2

Lifting the engine

40

3.3

Transport

42

3.3.1

Transport attachment

42

3.3.2

Transport device

43

3.4

4

Operating areas and maintenance areas

Storage

45

3.4.1

Storage

45

3.4.2

Storage time

49

Operation

51

4.1

Preliminary work for the initial commissioning of the engine

51

4.2

Starting the engine

52

4.3

Turning off the engine

54

Maintenance

55

5.1

Maintenance schedule

55

5.2

Preliminary work

58

5.2.1

Bringing the engine into maintenance position

58

5.2.2

As needed

58

5.3

Diesel engine

61

5.3.1

Checking the V-ribbed belt

61

5.3.2

Checking the belt drive

66

5.3.3

Checking the engine mount

73

5.3.4

Replacing the viscous damper

73

5.3.5

Checking the intake system for leaks and damage

76

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Contents

5.3.6 5.4

5.5

5.6

5.7

5.8

5.9

Checking the exhaust system

77

Lubrication system

78

5.4.1

Checking the engine oil system for leaks and damage

78

5.4.2

Checking the engine oil level

81

5.4.3

Changing the engine oil

82

Cooling system

88

5.5.1

Checking the cooling and heating system for leaks and damage

88

5.5.2

Checking the coolant level

89

5.5.3

Filling the coolant

89

5.5.4

Checking the concentration of the antifreeze agent in the coolant

90

5.5.5

Replacing the coolant

91

Fuel system

94

5.6.1

Checking the fuel system for leaks and damage

94

5.6.2

Checking the water separator on the fuel prefilter

95

5.6.3

Draining the water from the water separator in the fuel prefilter

95

5.6.4

Replacing the fuel prefilter

95

5.6.5

Reducing the pressure in the fuel system

96

5.6.6

Replacing the fuel fine filter

96

5.6.7

Ventilating the fuel system

99

Air filter

100

5.7.1

Checking the air filter low pressure indicator

100

5.7.2

Cleaning the air filter dust discharge valve

100

5.7.3

Replacing the dry air filter main element

100

5.7.4

Replacing the dry air filter safety element

100

Electrical system

101

5.8.1

Checking the batteries

101

5.8.2

Checking the cable connections

101

5.8.3

Lager Motorsteuergerät auf Schäden prüfen

101

5.8.4

Checking sensors, actuators, cable holders and plugs

102

5.8.5

Checking the heating flange

103

5.8.6

Replacing the heating flange

108

Exhaust aftertreatment assembly

112

5.9.1

Checking the exhaust aftertreatment assembly for leaks and damage

112

5.9.2

Checking the profile clamps

113

5.10 Lubricants and operating fluids

115

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Contents

Operator's manual

6

7

115

5.10.2 Engine oil

115

5.10.3 Coolant

116

5.10.4 Fuel

117

Malfunctions

119

6.1

119

Störungen - Ursache - Abhilfe

Tools and devices

125

7.1

125

7.2

8

5.10.1 Fill quantities

Tools 7.1.1

Special tool

125

7.1.2

Operating material

125

7.1.3

Diagnostic tools

126

Devices

127

7.2.1

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

127

7.2.2

Lifting traverse with two-point-raising

129

7.2.3

Engine assembly stand

130

7.2.4

Transport device

131

Appendix

133

8.1

Tightening torques

133

8.1.1

For hex bolts / cylinder screws / external hex bolts

133

8.1.2

For locking screws and banjo bolts

135

8.1.3

Standard torques for metric flange connections

136

8.1.4

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

137

8.1.5

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

138

8.1.6

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

138

8.1.7

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

139

8.1.8

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

140

8.2

Supplemental Information USA

144

8.2.1

Emission warranty

144

8.2.2

Warranted parts

144

8.2.3

RESPONSIBILITIES & LIMITATIONS

144

8.2.4

Exclusions

145

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1 Product description

1.1 Technical description 1.1.1 Design

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

Viscous damper Tension pulley Coolant pump V-ribbed belt Deflection pulley Alternator Oil separator

8 9 10 11 12 13 14

Cylinder head cover Air intake pipe Fuel high pressure pump Fuel fine filter Engine control unit Oil dipstick Oil pan

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Product description

Operator's manual

Technical description

Fig. 2: Flywheel side 1 2 3 4 5

Cable harness Lifting device Oil filler cap Exhaust manifold Exhaust gas turbocharger

6 7 8 9

Coolant outlet Coolant inlet Oil cooler Oil filter (2x)

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Product description Technical description

1.1.2 Exhaust aftertreatment system SCRonly

Fig. 3: Exhaust aftertreatment assembly 1 2 3 4

Sensor tube Outlet module Reducing agent injector Exhaust gas mixing tube

5 6 7 8

Inlet module NOx sensor Temperature sensor Reducing agent pump

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Product description

Operator's manual

Technical description

14 T

1

19

16

3 22 17

18 7 21

9 8

7

PAir

10

12

NOx

15

21 13

6

PTDEF

11

20

6 14 T

21 4

4

9

PAir

10

16

19

12

6

8

22

21

17

13 PTDEF

11

6 18 NOx

5

15

2

5

20

Fig. 4: Exhaust aftertreatment system 1 2

Coolant supply Coolant return

8 9

3 4

Compressed air Ventilation

10 11

5

Reducing agent intake module Reducing agent line heater Coolant control valve

6 7

15 16

NOx sensor Engine exhaust pipe

17 18

Exhaust gas mixing tube Inlet module

12

Reducing agent pump Reducing agent dosing system Air pressure sensor Reducing agent pressure and temperature sensor Air duct

19

Exhaust inlet (device side)

13 14

Reducing agent line SCR temperature sensor

20 21

Exhaust outlet Air control valve

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.

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Product description Technical description

Lamp Designation

Meaning

MIL lamp (Malfunction Indicator Lamp)

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

Reducing agent lamp

AWL lamp (Amber Warning Lamp)

Action required during the next maintenance

RSL lamp (Red Stop Lamp)

Engine stop required

HEST lamp (High Exhaust System Temperature)

High exhaust temperatures

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.

Note The restrictions occur in stages.

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Product description

Operator's manual

Technical description

Display (pictograms are examples)

System status

MIL off

Reducing agent level No restric< 10% or malfunction tion of exhaust aftertreatment system

Reducing agent lamp lights up yellow continuously.

Reducing agent level Low power < 5 % or malfunction limitation of exhaust aftertreatment system Acoustic signal Refill the reducing agent.

In case of malfuncReducing agent level High power tion, contact < 2.5 % or malfunc- limitation Liebherr customer tion of exhaust afterservice. treatment system

MIL flashes or lights up yellow continuously.

Reducing agent lamp flashes or lights up red continuously.

Acoustic signal

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

MIL flashes or lights up red continuously.

Reducing agent lamp flashes or lights up red continuously.

Remedy

Acoustic signal

MIL flashes or lights up yellow continuously.

Reducing agent lamp lights up yellow continuously.

Restrictions

Acoustic signal

Tab. 2: Exhaust aftertreatment system warning and malfunction strategies

Use / handling of reducing agent NOTICE Escaping reducing agent!

Damage to painted surfaces or aluminum surfaces.

Rinse affected surfaces with water immediately.

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Product description Technical description

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.

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.

1.1.3 Engine type itemization Description D 97 6 A7 -04 Engine type D

Engine type: D = diesel engine 97

Family (l/cylinder): 97: 3 l/cylinder 6

Number of cylinders A7

Injection system: A7 = Common Rail System Type, emission standard and exhaust aftertreatment system: -04 Emission standard: Stage IV / Tier 4 Exhaust aftertreatment system: SCRonly (Selective Catalytic Reduction) -05 Emission standard: Stage V Exhaust aftertreatment system: SCRonly (Selective Catalytic Reduction)

Tab. 3: Engine type itemization

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Product description

Operator's manual

Technical description

1.1.4 Company nameplate

Fig. 24: Company nameplate 1 2 3 4 5 6 7 8 9

Manufacturer 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

10 11 12 13 14 15 16 17 18

US performance category EU exemption Fuel minimum requirements EU type approval information ECE type approval information Chinese engine family Chinese emission limit stage Chinese type approval number Liebherr

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Product description Technical description

Attachment point

Fig. 25: Company nameplate on the engine 1

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..

2019 06 0001 Engine serial number 2019

Year of manufacture 06

Type series: 06 = D976 0001 Sequential production number

Tab. 4: Engine serial number

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Product description

Operator's manual

Technical description

1.1.5 Cylinder designation, direction of rotation Direction of rotation

6

5

4

3

2

1

Fig. 26: Cylinder designation and direction of rotation 1

Flywheel side

2

Unit carrier side

= Outlet valve = Inlet valve Cylinder 1 is located on the unit carrier side 2.

Viewed from the flywheel side 1, the crankshaft turns counterclockwise.

1.1.6 Engine control unit type plate

Fig. 27: Engine control unit type plate (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

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Product description Technical description

Attachment point

Fig. 28: Attachment point 1

Engine control unit type plate

1.1.7 Exhaust aftertreatment system type plate Type plate

Ý«­¬±³»® ×Ü

ïïíèîëêè

ÍÛÎ×ßÔ Ò±ò

ÔÎßðëêëçî

ÍËÐÐÔ×ÛÎ ÐßÎÌ Ò±ò ú ×ÍÍËÛ ÔÛÊÛÔ

ÉÍÈÈïêê

ÓßÒËÚßÝÌËÎÛ ÜßÌÛ

ÜÜ ñ ÓÓ ñ ÇÇ

Fig. 29: Sample type plate 1 2 3

Data matrix code Identification number Serial number

4 5

Supplier part number Date of manufacture

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Product description

Operator's manual

Technical description

Attachment point

Fig. 30: Type plate on DOC, exhaust gas mixing tube and sensor tube 1

Type plate for individual components

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Product description Technical description

Fig. 31: Type plate on inlet module and outlet module 1

Type plate for individual components

2

Type plate for complete system

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Product description

Operator's manual

Technical data

1.2 Technical data 1.2.1 Diesel engine D976 A7-04 / D976 A7-05 Description

Unit Value

Construction

In-line diesel engine

Number of cylinders

6

Firing order

1–5–3–6–2–4

Hole

mm 148

Stroke

mm 174

Displacement

l 18

Compression ratio

16,5:1

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 Coolant thermostat Description

Unit Value

Start of opening

°C 82

Completely opened

°C 92

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2 Safety

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

Tab. 5 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. 6

2.2 Additional labels Note Identifies useful information and tips.

Tab. 7

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Safety

Operator's manual

Foreseeable misuse

2.3 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.

2.4 Intended use – Use the engine for the intended purpose.

– Observe the following conditions from the manufacturer: • Operating conditions • Maintenance conditions • Servicing conditions – Ensure that the following activities are only performed by persons according to the target group definition: • Use engine.

• Maintain engine.

• Service engine.

– Install contactors and protective devices prior to commissioning.

Ensure the function of the contactors.

– Observe safety instructions and operating instructions.

– Operate the engine in flawless condition.

– Operate the engine in the speed range prescribed by the manufacturer.

– Screw the engine with the attached engine brackets to the machine or to the respective operation site with the respective tensioning instructions.

– Only operate the engine with the engine brackets or engine mounts approved or installed by the manufacturer.

– Only operate the engine in areas that are not publicly accessible.

– Only operate the engine with an enclosure or engine compartment cover.

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 of the test range (NTE range) for the corresponding engine category.

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

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

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Safety General safety instructions

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

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

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

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

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

2.6 General safety instructions – Requirements to be met by the target audiences for work. See the “Target audience” chapter.

– To guarantee assistance after an accident: Make sure a second person is in attendance or that the emergency situation is detected and help provided.

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

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

• Observe generally accepted occupational health and safety regulations.

• Observe the operating and maintenance manual.

– Ensure that the personnel wear safe working clothes.

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

– Keep the workplace clean and tidy.

– Take precautions for any emergency that may occur.

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

– Keep the emergency telephone numbers close by.

– Make sure that the workplace is well lit.

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

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Safety

Operator's manual

General safety instructions

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

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Safety Preventing personal injuries

2.7 Preventing personal injuries 2.7.1 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 in accordance with its operating 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.

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

– If the diesel engine is running, make sure that no objects can come into contact with rotating parts. Objects may be flung back.

2.7.2 Burns and scalds The engine at operating temperature is hot.

– Only work on the cooled down engine.

– Touch hot parts with thermal protection gloves.

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

– Touch hot parts with thermal protection gloves.

– Avoid contact with parts carrying cooling water.

– When the end cover of the expansion tank has cooled down: Check the cooling water level.

– Open the lid carefully in order to release the overpressure.

When the engine is at operating temperature, the engine oil is hot.

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

2.7.3 Fires and explosions – Smoking is prohibited in the direct vicinity of the diesel engine.

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

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

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

– Wear safety goggles and gloves when working on batteries.

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

– Disconnect the power supply when working on the electrical system.

2.7.4 Poisoning – – – –

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

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

Never ingest any operating materials.

Do not use drinking bottles for storage purposes.

Escaping liquids can penetrate the skin and cause blood poisoning.

– Do not open any pressurized lines or hoses.

– Do not disconnect any pressurized lines or hoses.

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

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Personal protective equipment

2.7.5 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.

2.7.6 Electrical energy – The safety zones around the operational Diesel engine may not be accessed by persons with a heart pacemaker.

– Do not touch any live parts.

– Disconnect the power supply before any work on the electrical system.

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

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

– Do not stand near the running engine without hearing protection that is suitable for the noise level.

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

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

2.8 Personal protective equipment – Wear protective equipment during direct access to diesel engines.

– Ensure that: • Protective equipment is in good condition.

• Protective function is guaranteed.

The following protective equipment is required to access the engine: Protective work wear – Close-fitting, non-tear-resistant protective clothing as protection against injuries and simple chemical substances Wear protective work gear in the direct vicinity of the engine.

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Safety Operating areas and maintenance areas

Safety helmet – Protection against falling or flying objects and against knocks to the head Wear a safety helmet in the immediate vicinity of the engine.

Safety shoes – Protect feet against falling objects and from getting caught in heavy parts. Additional protection against slipping Wear safety shoes in the immediate vicinity of the engine.

Safety gloves – Protection against hot elements and chemicals Wear safety gloves during work with hot parts. (For example: shrink-fitting the crown gear on the flywheel.)

Wear safety gloves during work with operating materials. (Please refer to the manufacturer's specifications for the operating materials and the safety data sheet for the operating material.)

Hearing protection – Protection against noise Wear hearing protection near running engines.

Safety goggles – Protection against flying splinters and chemical splashes Wear safety goggles when handling operating materials. (Please refer to the manufacturer's specifications for the operating materials and the safety data sheet for the operating material.)

Wear safety goggles during mechanical operations. (For example when using compressed air) Gas detector – Protection against escaping gases Wear a gas detector when working on the engine.

2.9 Operating areas and maintenance areas 2.9.1 Safety instructions Trapping points and mechanical parts flying around when the engine is ready for operation or in operation Serious injuries and risk of death: – Keep away from the operational engine.

– Wear personal protective equipment.

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

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

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

– Wear personal protective equipment.

– Let the engine cool down sufficiently.

High electric short-circuit currents during maintenance work

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Operating areas and maintenance areas

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.

2.9.2 Operating areas A

D

B

B

B

B

C

E

a

b

Fig. 44: 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

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

WARNING Hot components on the engine Serious burns possible.

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

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Safety Operating areas and maintenance areas

A

D

B

B

B

B

C

E

a

b

Fig. 45: 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

2.9.4 Secure and release the diesel engine against accidental starting Access to the maintenance areas must be secured against accidental starting 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.

– Remove the label from the fuel supply.

– Reconnect the fuel supply.

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Signage

– Remove the label from the electrical power supply.

– Establish the electrical power supply.

2.9.5 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.

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

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

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

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

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

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

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

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

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

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

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

Secure the Diesel engine against any unexpected start-up.

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

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

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Safety Prevent material damages

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

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

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

2.11 Prevent material damages – Replace jointing material (e.g. O-rings, seals etc.).

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

– Replace any removed parts that cannot be re-used.

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

– Replace self-locking screwed connections.

– Clean the diesel engine, connections and screw connections thoroughly of oil, fuel or care products before assembly.

– Use lint-free cleaning rags.

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

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

– Remove the covers/seals after cleaning.

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

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

– Use suitable test leads for measurements at plug connections.

– Protect the engine control unit against dust and water if no mating plug has been connected.

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Prevent material damages

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3 Transport and storage

3.1 Dimensions and weights

2

1

3

Fig. 51: Dimensions 1 2

Width Height

3

Length

Description

Unit Value

Width

mm 997

Height

mm 1262

Length

mm 1548

Engine weight without operating fluids

kg 1900

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

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Lifting the engine

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

Leads to death or serious injuries.

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 127) Remove the gearbox or other attachments before lifting the engine.

Take safety instructions / warning signs from the operating instructions 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). 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. 52: Lifting the engine A

Transport device detail view

1

B

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

2

Tolerance for maximum deviation of motor axis Crankcase

3

Lifting traverse

C

See next page for continuation of the image legend

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Transport and storage Lifting the engine

D

Front / rear view of lateral transport device

4

E

Lifting traverse lifting point detail view

5

F

Take lifting traverse warning signs, lifting traverse operating instructions into account.

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

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

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Transport

3.3 Transport 3.3.1 Transport attachment

Fig. 53: Transport attachment

DANGER Instability during transport!

Leads to death or serious injuries.

Only use the original transport device.

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

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

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

Observe the center of gravity.

Bolt the engine securely to the transport device.

DANGER The engine can tip during loading or unloading!

Leads to death or serious injuries.

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

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

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

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

Observe information on the center of gravity.

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Transport and storage Transport

3.3.2 Transport device Wood transport device DANGER Instability during transport!

Leads to death or serious injuries.

Only use the original transport device.

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

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

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

Observe the center of gravity.

Bolt the engine securely to the transport device.

Fig. 54: Wood transport device Only transport the engine using the transport device.

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Transport

Steel transport device DANGER Instability during transport!

Leads to death or serious injuries.

Only use the original transport device.

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

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

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

Observe the center of gravity.

Bolt the engine securely to the transport device.

Fig. 55: Steel transport device Only transport the engine using the transport device.

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Transport and storage Storage

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

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

Use the “first in first out” logistics method.

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

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

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

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

Burns.

Refrain from open flames.

Refrain from smoking.

VCI film cover LxWxH ID no.

2100x1100x2150

10165707

1250x850x1500

10042128

1250x850x2100

11694088

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Storage

VCI film cover LxWxH ID no.

990x540x1300

11067328

2000x1500x2000

11826670

3200x1500x2000

11826671

540x350x540

11067327

350x250x550

11067326

850x650x800

10331822

Tab. 8: VCI film cover VCI bag LxW ID no.

300x200

11170517

345x260

11170521

Tab. 9: VCI bag Loosely apply the VCI corrosion protection film so it is sealed tight.

Air can circulate.

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

Disposal CAUTION Chemical substances!

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

Use protective gloves.

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

Dispose of VCI corrosion protection film.

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

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

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

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

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

Drying time is 3 hours.

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Transport and storage Storage

Name

Description

ID no.

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

Tab. 10: Corrosion protection wax A)

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

WARNING Corrosion protection wax is highly flammable!

Burns.

Refrain from open flames.

Refrain from smoking.

NOTICE Decommissioning at freezing temperatures!

Damage to engine.

Contact customer service.

Remove the engine from the device or system.

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

CAUTION Wax residues on the floor!

Slipping.

Watch out for wax residues on the floor.

Remove wax residues on the floor.

Clean engine.

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

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

Check the engine for damage.

Check the engine for paint damage.

If any damage exists: Repair the damage.

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

Disposal Properly dispose of corrosion protection wax.

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

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Storage

Corrosion protection wax de-preservation See Cleaning chapter.

Cleaning Cleaning with cleaning agents NOTICE Impermissible cleaning agent!

Damage to surfaces and sealing elements.

Only use suitable, mild cleaning agents.

Only use lint-free cleaning cloths.

Remove lubricant and contaminants.

Remove water residues.

Warm up the engine.

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

Damage to the electronics and seals of the engine.

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

Prerequisites: Shafts and flanges are lubricated.

Openings are covered or taped with protecting caps and guards.

Seals and closures are tight.

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

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

NOTICE Steam jet comes in contact with temperature sensors!

Activation of the extinguishing system.

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

NOTICE High pressure cleaner comes in contact with sensitive components!

Damage to the electronics and seals of the engine.

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

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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. 11: Storage time Observe the storage time.

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Storage

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4 Operation

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

Provide a suitable engine oil for the engine. (For more information see: 5.10.2 Engine oil, page 115) Fill the oil.

Check oil filter connection.

Provide coolant with the correct coolant composition. (For more information see: 5.5.4 Checking the concentration of the antifreeze agent in the coolant, page 90) 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: 5.10.4 Fuel, page 117) Fill the diesel fuel. (For more information see: Minimum requirement for the quality, page 117) Ventilate the fuel system. (For more information see: 5.6.7 Ventilating the fuel system, page 99) 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.

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Starting the engine

4.2 Starting the engine Make sure that the following prerequisites are met: During the initial commissioning: Preliminary work for the initial commissioning of the engine has been performed. (For more information see: 4.1 Preliminary work for the initial commissioning of the engine, page 51) 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 55) 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 Störungen - Ursache - Abhilfe, page 119) NOTICE Continuous operation!

Damage to starter.

Let the starter run a maximum of 30 seconds.

Start the engine.

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

Start the engine.

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Operation Starting the engine

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

Start the engine.

If the engine does not start with the third attempt: Determine cause and rectify. (For more information see: 6.1 Störungen - Ursache - Abhilfe, page 119) Check oil pressure gauge immediately after starting the engine.

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

Determine cause and rectify. (For more information see: 6.1 Störungen - Ursache - Abhilfe, page 119) NOTICE Impermissible loading of the engine in cold condition!

Damage to engine.

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

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

Coolant temperature >60 °C

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Turning off the engine

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

Damage to engine.

Turn off the engine at idling speed.

Reduce engine speed to idling speed.

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

Turn off the engine.

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5 Maintenance

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

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

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

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

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

500 h

Diesel engine Check the belt drive.

66

1000 h

Check the engine mount.

73

500 h

1000 h

Check intake system for leaks and damage.

76

500 h

1000 h

Check exhaust system.

77

500 h

Checking the V-ribbed belt

61

3000 h

Replacing the V-ribbed belt

62

6000 h

Replacing the belt drive

67

10000 h

Replace viscous damper.

Lubrication system Check engine oil system for leaks and damage.

73

Check engine oil level.

81

Changing the engine oil and oil filter

82

10 h

Cooling system Check coolant level.

89

500 h

Check cooling and heating system for leaks and damage.

88

Check the concentration of the antifreeze agent.

90

Replace coolant.

91

10 h

Fuel system Check the water separator on the fuel prefilter.

95

500 h

Check fuel system for leaks and damage.

94

1500 h

Replace fuel prefilter.

95

1500 h

96

10 h

Replace fuel fine filter.

Air filter Check the air filter low pressure indicator.

50 h

Clean the air filter dust discharge valve.

100

Replace the dry air filter main element.

100 100

500 h

Replace the dry air filter safety element.

Electrical system Lager Motorsteuergerät auf Schäden prüfen.

1500 h

Check the batteries.

101

1500 h

Check the cable connections.

101

1500 h

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

102

Check heating flange, if present.

103

Replace heating flange, if present.

108

10 h 10 h 1500 h / every two years

6000 h / every four years

500 h

10000 h

78

100

101

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Maintenance Maintenance schedule

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

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

10 h 50 h

1000 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

Exhaust aftertreatment assembly Checking the exhaust aftertreatment assembly for leaks and damage Check components

112 113

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Preliminary work

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

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

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

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

5.2.2 As needed Removing the cylinder head cover Disconnecting the crankcase ventilation line from the cylinder head cover

Fig. 56: Removing the cylinder head cover 1 2

Hose nipple Clamp

4 5

External hex bolt (20x) Cylinder head cover

See next page for continuation of the image legend

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Maintenance Preliminary work

3

Hose

6

Seal

4 5 6

External hex bolt (20x) Cylinder head cover Seal

Release clamp 2.

Remove hose 3 from hose nipple 1.

Removing the cylinder head cover Unscrew external hex bolt 4.

Remove seal 6.

Remove cylinder head cover 5.

Installing the cylinder head cover

Fig. 57: Installing the cylinder head cover 1 2 3

Hose nipple Clamp Hose Replace seal 6.

Align new seal 6.

Install cylinder head cover 5.

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Preliminary work

Tightening instruction for M10X120 8.8 FLZN hex nut Tightening sequence

Lubricant

-

Locking agent

-

Part contact surfaces

-

Screws

Reusable

Stage

Tightening torque

1.

46 ±6 Nm

Tab. 12: Tightening instruction Tighten external hex bolts 4 according to the tightening instruction.

Installing the crankcase ventilation line on the cylinder head cover Slide hose 3 onto hose nipple 1.

Tighten clamp 2.

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Maintenance Diesel engine

5.3 Diesel engine 5.3.1 Checking the V-ribbed belt

Fig. 59: 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

Variants of the belt drive

2

5

6

2

5

6

3

3

4 5

1

1

Fig. 60: Belt drive variants 1 2 3

Crankshaft belt pulley Alternator Tension pulley

4 5 6

Air conditioning compressor Deflection pulley Coolant pump belt pulley

Check V-ribbed belt for damage. copyright © Liebherr-Components Colmar SAS 2019

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

Replacing the alternator 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. 61: Removing the V-ribbed belt 1 2

Tension pulley Internal square

3

V-ribbed belt

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

Swivel back the tension pulley 1 counterclockwise against the spring force to the limit stop.

The V-ribbed belt 3 is free.

Remove the V-ribbed belt 3.

Turn back tension pulley 1.

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Maintenance Diesel engine

Installing the V-ribbed belt

Fig. 62: Installing the V-ribbed belt 1 2

Tension pulley Internal square

3

V-ribbed belt

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

Swivel back the tension pulley 1 counterclockwise against the spring force to the limit stop.

Install V-ribbed belt 3.

Turn tension pulley 1 back carefully.

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.

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Diesel engine

Fig. 63: Removing the V-ribbed belt 1 2

Tension pulley Internal square

3

V-ribbed belt

If a fan is present: Remove fan.

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

Swivel back the tension pulley 1 counterclockwise against the spring force to the limit stop.

The V-ribbed belt 3 is free.

Remove the V-ribbed belt 3.

Turn back tension pulley 1.

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Maintenance Diesel engine

Installing the V-ribbed belt

Fig. 64: Installing the V-ribbed belt 1 2

Tension pulley Internal square

3

V-ribbed belt

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

Swivel back the tension pulley 1 counterclockwise against the spring force to the limit stop.

Install V-ribbed belt 3.

Turn tension pulley 1 back carefully.

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Diesel engine

5.3.2 Checking the belt drive Checking the alternator belt drive

Fig. 65: Components 1 2 3

Crankshaft belt pulley Tension pulley Coolant pump

4 5 6

Deflection pulley Alternator Deflection pulley

Check components for damage.

If components are damaged: Do not start engine.

Replace defective components, see repair manual.

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Maintenance Diesel engine

Checking the alternator belt drive

Fig. 66: Components 1 2 3

Crankshaft belt pulley Tension pulley Coolant pump

4 5 6

Deflection pulley Alternator Air conditioning compressor

Check components for damage.

If components are damaged: Do not start engine.

Replace defective components, see repair manual.

Replacing the alternator belt drive Make sure that the following prerequisites are met: The V-ribbed belt is removed.

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Diesel engine

Removing the belt drive

Fig. 67: Removing the belt drive 1 2 3

External hex bolt External hex bolt Tension pulley

4 5 6

External hex bolt Deflection pulley Deflection pulley

Unscrew external hex bolt 2.

Remove tension pulley 3.

Unscrew external hex bolt 1.

Remove deflection pulley 6.

Unscrew external hex bolt 4.

Remove deflection pulley 5.

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Installing the alternator belt drive

Fig. 68: Installing the belt drive 1 2 3

External hex bolt External hex bolt Tension pulley

4 5 6

External hex bolt Deflection pulley Deflection pulley

Install tension pulley 3.

Tensioning instruction for M10X80 8.8 FLZN external hex bolt Lubricant

-

Locking agent

LOCTITE 243

Part contact surfaces

-

Screws

-

Stage

Tightening torque

1.

50 ±5 Nm

Tab. 13: Tightening instruction Tighten external hex bolt 2 according to the tightening instruction.

Install deflection pulley 5.

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Diesel engine

Tightening instruction for M10x60 deflection pulley Lubricant

-

Locking agent

LOCTITE 243

Part contact surfaces

-

Screws

not reusable

Stage

Tightening torque

1.

48 ±8 Nm

Tab. 14: Tightening instruction Tighten external hex bolt 4 according to the tightening instruction.

Install deflection pulley 5.

Tightening instruction for M10x60 deflection pulley Lubricant

-

Locking agent

LOCTITE 243

Part contact surfaces

-

Screws

not reusable

Stage

Tightening torque

1.

65 ±5 Nm

Tab. 15: Tightening instruction Tighten external hex bolt 4 according to the tightening instruction.

Replacing the alternator belt drive Make sure that the following prerequisites are met: The V-ribbed belt is removed.

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Maintenance Diesel engine

Removing the belt drive

Fig. 72: Removing the belt drive 1 2

External hex bolt Tension pulley

3 4

External hex bolt Deflection pulley

Unscrew external hex bolt 1.

Remove tension pulley 2.

Unscrew external hex bolt 3.

Remove deflection pulley 4.

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Diesel engine

Installing the alternator belt drive

Fig. 73: Removing the belt drive 1 2

External hex bolt Tension pulley

3 4

External hex bolt Deflection pulley

Install tension pulley 2.

Tensioning instruction for M10x100 8.8 FLZN external hex bolt Lubricant

-

Locking agent

LOCTITE 243

Part contact surfaces

-

Screws

-

Stage

Tightening torque

1.

50 ±5 Nm

Tab. 16: Tightening instruction Tighten external hex bolt 1 according to the tightening instruction.

Install deflection pulley 4.

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Maintenance Diesel engine

Tightening instruction for M10x60 deflection pulley 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.

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

5.3.4 Replacing the viscous damper Removing the viscous damper Make sure that the following prerequisites are met: The V-ribbed belt is removed.

Viscous damper is ready.

Graphic representation

Description

Required number

Identification number

M22x180 assembly pin (viscous damper)

2

tbd

Tab. 18: Special tool

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Diesel engine

Fig. 77: Removing the viscous damper 1 2

External hexalobular bolt (6x) Spacer

3 4

Viscous damper Crankshaft belt pulley

Unscrew the two opposing external hexalobular bolts 1.

Tighten two assembly pins.

Unscrew external hexalobular bolts 1 in reverse order of the tensioning instruction. (see: tab. 19, page 75) Remove spacer 2.

Remove viscous damper 3.

Cleaning Clean contact surfaces of the spacer 2.

Clean contact surfaces of the viscous damper 3.

Clean contact surfaces of the crankshaft belt pulley 4.

Installing the viscous damper Tighten two assembly pins.

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Maintenance Diesel engine

Fig. 78: Installing the viscous damper 1 2

External hexalobular bolt (6x) Spacer

3 4

Viscous damper Crankshaft belt pulley

Install viscous damper 3.

Install spacer 2.

Screw in external hexalobular bolt 1.

Unscrew assembly pin. (see: tab. 18, page 73) Tightening instruction for M22x1.5x146 external hexalobular bolt Lubricant

Engine oil

Locking agent

-

Part contact surfaces

Degreased

Screws

Not reusable

Stage

Tightening torque

1.

120 Nm

Stage

Angle of rotation

3.

180°

4.

45°

Tightening sequence

Tab. 19: Tightening instruction Tighten external hexalobular bolts 1 according to the tightening instruction. (see: tab. 19, page 75)

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Diesel engine

5.3.5 Checking the intake system for leaks and damage

Fig. 80: Components to be checked 1 2 3

External hex bolt Pipeline Intermediate flange/heating flange

4 5 6

Seal Air intake pipe Locking part

Check components for leaks.

If components are leaking: Do not start engine.

Replace components, see repair manual.

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.

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Replace damaged components, see repair manual.

Check device side suction lines between the air intake pipe 5 and exhaust gas turbocharger, see documentation from the device manufacturer.

5.3.6 Checking the exhaust system

Fig. 81: Components to be checked 1 2

Manifold seal Exhaust manifold

3

Exhaust gas turbocharger

Check components for damage.

Check components for leaks.

Check components for tight fit.

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

Connection points between exhaust gas turbocharger 3 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 manual.

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Lubrication system

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

Serious burns possible.

Let the engine cool down to ambient temperature.

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

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

Damage to health and environmental damage possible.

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

Make sure that no lubricant gets into the environment.

Observe national and international guidelines for disposal.

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Fig. 82: Components to be checked 1 2 3

Oil pan Cylinder head gasket Cylinder head cover seal

4 5 6

Crankcase ventilation Oil filler cap Oil dipstick

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Lubrication system

Fig. 83: Components to be checked 1 2

Oil filter Oil cooler

3 4

Supply line Return line

Check components for leaks.

If components are leaking: Do not start engine.

Replace components, see repair manual.

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 repair manual.

Check oil loss at other components of the engine oil system.

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

Damage to health and environmental damage possible.

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

Make sure that no lubricant gets into the environment.

Observe national and international guidelines for disposal.

Fig. 84: Filling the engine oil 1 2

Oil filler cap Oil filler neck

3

Oil dipstick

Start the engine.

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

Wait 5 minutes.

Pull out oil dipstick 3.

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

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Lubrication system

Insert oil dipstick 3.

Pull out oil dipstick 3.

Fig. 85: Oil dipstick 1

Maximum

2

Minimum

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

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

If the oil level is below the Minimum 2 mark: Refill oil.

Insert oil dipstick 3.

Check oil level again.

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

The engine is turned off.

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

A suitable drain hose is available.

Engine oil is available.

Engine oil specification

Draining the engine oil Make sure that the following prerequisites are met: A suitable collection container is available.

Graphic representation

Description

Drain hose

Required number

Identification number

1

12690422

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Graphic representation

Description

Drain hose 90°

Required number

Identification number

1

12690423

Tab. 20: Special tool WARNING Hot components on the engine Serious burns possible.

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

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

Damage to health and environmental damage possible.

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

Make sure that no lubricant gets into the environment.

Observe national and international guidelines for disposal.

Fig. 88 1 2

Sealing cap Oil drain valve

3

Drain hose

Place end of drain hose 3 in collection container. copyright © Liebherr-Components Colmar SAS 2019

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Lubrication system

Unscrew sealing cap 1 from oil drain valve 2.

Install drain hose 3 on oil drain valve 2.

Oil drain valve 2 is opened.

Engine oil runs out.

Remove drain hose 3.

Tighten sealing cap 1 on oil drain valve 2.

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

Replacing the oil filter Removing the oil filter WARNING Hot components on the engine Serious burns possible.

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

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

Damage to health and environmental damage possible.

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

Make sure that no lubricant gets into the environment.

Observe national and international guidelines for disposal.

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Fig. 89: Removing the oil filter 1

Oil filter cooler

2

Oil filter (2x)

Unscrew oil filter 2.

Cleaning Clean sealing surface with a lint-free cloth.

Installing the oil filter WARNING Hot components on the engine Serious burns possible.

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

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

Damage to health and environmental damage possible.

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

Make sure that no lubricant gets into the environment.

Observe national and international guidelines for disposal.

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Lubrication system

Fig. 90: Installing the oil filter 1

Oil filter cooler

2

Oil filter (2x)

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

Screw on new oil filter 2.

Tightening instruction for oil filter Lubricant

-

Locking agent

-

Part contact surfaces

Engine oil

Screws

-

Stage

Tightening torque

1.

Screw on by hand until the seal is in contact

2.

3/4 - 1 revolution (20 -5 Nm)

Tab. 21: Tightening instruction Tighten new oil filter 2 according to the tightening instruction.

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Filling the engine oil

Fig. 92: Filling the engine oil 1 2

Oil filler cap Oil filler neck

3

Oil dipstick

Unscrew oil filler cap 1.

Fill oil via oil filler neck 2.

Check engine oil level.

Insert oil dipstick 3.

Check oil level again.

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

Clean oil filler cap 1.

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

Start the engine.

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

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Cooling system

5.5 Cooling system 5.5.1 Checking the cooling 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. 93: Components to be checked 1 2 3 4

Drain valve Oil cooler Coolant ventilation Coolant outlet

5 6 7

Cylinder head gasket Coolant pump Coolant inlet

Check components for leaks.

If components are leaking: Do not start engine. copyright © Liebherr-Components Colmar SAS 2019

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Replace components, see repair manual.

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 repair manual.

Check coolant at other components of the cooling and heating system.

5.5.2 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: 5.5.4 Checking the concentration of the antifreeze agent in the coolant, page 90)

5.5.3 Filling the coolant Fill the coolant via the device side filler neck. (For more information see: Correcting the concentration of the antifreeze agent, page 90) 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 54) Let the engine cool down.

Check coolant level. (For more information see: 5.5.2 Checking the coolant level, page 89) If the coolant level is too low or too high: Correct the coolant level, see documentation from the device manufacturer.

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Cooling system

5.5.4 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. 94, page 90) .

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

Coolant fill quantity in liters

2

Measured concentration in vol. %

3

Refilling quantity of antifreeze agent in liters

Drain the calculated refilling quantity from the cooling system.

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

Fill the calculated refilling quantity of the antifreeze agent.

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Maintenance Cooling system

5.5.5 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 Make sure that the following prerequisites are met: A suitable collection container is available.

Graphic representation

Description

Required number

Identification number

Drain hose

1

12690422

Drain hose 90°

1

12690423

Tab. 22: Special tool DANGER Hot cooler parts and hot coolant!

Serious burns possible.

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

Wear protective gloves and safety goggles.

NOTICE Escaping coolant!

Injuries Avoid skin contact with coolant.

Follow the manufacturer's instructions.

When mixing coolant, wear rubber gloves and safety goggles.

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

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Cooling system

Fig. 97: Draining the coolant 1 2

Sealing cap Drain valve

3 4

Drain hose Drain plug

Unscrew sealing cap 1.

Put collection container under drain plug 4.

Unscrew drain plug 4.

Coolant runs into collection container.

Tighten drain plug 4.

Place end of drain hose 3 in collection container.

Install drain hose 3.

Coolant runs into collection container.

Remove drain hose 3.

Tighten sealing cap 1.

Filling the coolant Fill the coolant via the device side filler neck. (For more information see: Correcting the concentration of the antifreeze agent, page 90) 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 54) Let the engine cool down.

Check coolant level. (For more information see: 5.5.2 Checking the coolant level, page 89) copyright © Liebherr-Components Colmar SAS 2019

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

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Fuel system

5.6 Fuel system 5.6.1 Checking the fuel system for leaks and damage Make sure that the following prerequisite is met: Cylinder head cover is removed. (For more information see: Removing the cylinder head cover, page 58) 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. 98: Components to be checked 1 2

Fuel line Fuel return line

5 6

Fuel fine filter console Fuel high pressure pump

See next page for continuation of the image legend

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3 4

Injection line Rail

7

Fuel fine filter

Check components for leaks.

If components are leaking: Do not start engine.

Replace components, see repair manual.

Check components for proper fastening.

If components are loose: Do not start engine.

Tighten components.

Check components for damage.

If components are damaged: Do not start engine.

Replace damaged components, see repair manual.

5.6.2 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: 5.6.3 Draining the water from the water separator in the fuel prefilter, page 95)

5.6.3 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.

5.6.4 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.

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

NOTICE Dirt!

Damage to Common Rail System.

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

Do not reuse the fuel filter.

Observe instructions for work on the Common Rail System.

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

Ventilate the fuel system. (For more information see: 5.6.7 Ventilating the fuel system, page 99)

5.6.5 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 126) Pressure below 10 bar

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

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Fig. 99: Replacing the fuel fine filter 1

Fuel fine filter

2

Fuel fine filter console

If the engine is running: Turn off the engine.

Wait 20 minutes.

Check pressure reduction with diagnostics software (variables: 6996 - Fuel Pressure High 1/ 6997 - Fuel Pressure High 2). (For more information see: 7.1.3 Diagnostic tools, page 126) If the pressure is below 10 bar: Put a collection container under the fuel fine filter.

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

Clean the fuel fine filter console 2 and surrounding area.

Remove fuel fine filter 1.

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

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

Installing the fuel fine filter NOTICE Dirt!

Damage to Common Rail System.

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

Do not reuse the fuel filter.

Observe instructions for work on the Common Rail System.

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Fig. 100: Replacing the fuel fine filter 1

Fuel fine filter

2

Fuel fine filter console

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

Tightening instruction for fuel fine filter Lubricant

-

Locking agent

-

Part contact surfaces

Engine oil

Screws

-

Stage

Tightening torque

1.

Screw on by hand until the seal is in contact

Stage

Angle of rotation

2.

by hand 1/2 - 3/4 of a revolution

Tab. 23: Tightening instruction Tighten new fuel fine filter 1 according to the tightening instruction.

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

Ventilate the fuel system. (For more information see: 5.6.7 Ventilating the fuel system, page 99)

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5.6.7 Ventilating the fuel system

3

1

2

4

5

6

Fig. 102: Fuel diagram, external system 1 2 3

Connection to engine Fuel air cooler (optional) Fuel prefilter

4 5 6

Water separator Manual ventilation pump Fuel tank

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

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

Wait 1 minute.

Pressure escapes through ventilation.

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

Wait until the pressure has been relieved through ventilation.

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

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Air filter

5.7 Air filter 5.7.1 Checking the air filter low pressure indicator For procedure to check the air filter low pressure indicator, see documentation from the device manufacturer.

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

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

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

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5.8 Electrical system 5.8.1 Checking the batteries Check components for contamination, see documentation from the device manufacturer.

Check components for mechanical damage, see documentation from the device manufacturer.

5.8.2 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.

5.8.3 Lager Motorsteuergerät auf Schäden prüfen

Fig. 103: Motorsteuergerätelagerung 1

Lager Motorsteuergerät Lager Motorsteuergerät 1 auf Schäden prüfen.

Lager Motorsteuergerät 1 auf festen Sitz prüfen.

Wenn Lager beschädigt oder verschlissen sind: Motor nicht starten.

Lager ersetzen, siehe Reparaturanleitung.

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Electrical system

5.8.4 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. 104: Unit carrier side sensors 1 2 3 4 5

Speed sensor Cycle valve Temperature sensor Pressure and temperature sensor Pressure sensor

6 7 8 9

Rail pressure sensor Temperature sensor Suction throttle valve High pressure regulating valve

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Fig. 105: Flywheel side sensors 1

Speed sensor

2

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.

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

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

Disconnect the negative cable from the battery.

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Electrical system

Fig. 106: Removing the cable from the heating flange 1 2

Connection Cable

3

Nut

Unscrew nut 3.

Remove cable 2 from connection 1.

Tightening instruction for M6 hex nuts Lubricant

-

Locking agent

-

Part contact surfaces

-

Screws

Reusable

Stage

Tightening torque

1.

12 ±2.5 Nm

Tab. 24: Tightening instruction

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Tightening instruction for M6 hex nuts Lubricant

-

Locking agent

-

Part contact surfaces

-

Screws

Reusable

Stage

Tightening torque

1.

7.75 ±1.25 Nm

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

Connect ohmmeter or multimeter to connections 1.

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

Measure the resistance.

If the resistance at 20 °C falls below 230 ±23 m : Replace the heating flange. (For more information see: 5.8.6 Replacing the heating flange, page 108)

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Fig. 109: Installing the cable of the heating flange 1 2

Connection Cable

3

Nut

Install cable 2 on connection 1.

Tightening instruction for M6 hex nuts Lubricant

-

Locking agent

-

Part contact surfaces

-

Screws

Reusable

Stage

Tightening torque

1.

8 ±1 Nm

Tab. 26: Tightening instruction Tighten nut 3 according to the tightening instruction.

Connect negative cable to battery.

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Checking the heating flange for sooting Make sure that the following prerequisites are met: Air intake pipe is removed. (For more information see: 5.8.6 Replacing the heating flange, page 108)

Fig. 111: Checking the heating flange for sooting 1

Heating flange Check heating flange 1 for sooting.

NOTICE Undiscovered damage on the turbocharger!

Oil residues in air intake pipe.

Check turbocharger.

Check air intake pipe for oil residues.

Check air intake pipe for sooting.

If the heating flange 1 is sooted: Remove heating flange 1. (For more information see: 5.8.6 Replacing the heating flange, page 108) Clean heating flange 1 with brake cleaner.

Remove brake cleaner residues from heating flange 1.

Install heating flange 1. (For more information see: 5.8.6 Replacing the heating flange, page 108)

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5.8.6 Replacing the heating flange Removing the charging pressure line

Fig. 112: Removing the charging pressure line 1 2

External hex bolt Sealing ring

3

Pipeline with banjo fittings

Unscrew external hex bolt 1.

Remove sealing ring 2.

Remove pipeline with banjo fittings 3.

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Removing the heating flange

Fig. 113: Removing the heating flange 1 2 3

Seal Heating flange Heating flange flow direction

4 5 6

Air intake pipe External hex bolts Screw plug

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 2.

Unscrew screw plug 6.

Unscrew external hex bolts 5.

Remove air intake pipe 4.

Remove seal 1.

Remove heating flange 2.

Remove seal 1.

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Installing the heating flange

Fig. 114: Removing the heating flange 1 2 3

Seal Heating flange Heating flange flow direction

4 5 6

Air intake pipe External hex bolts Screw plug

Install seal 1.

Note Observe heating flange flow direction 3.

Install heating flange 2.

Install seal 1.

Install air intake pipe 4.

Tighten external hex bolts 5.

Tightening instruction for VSTI M30X1.5 ED-FPM screw plug Lubricant

-

Locking agent

-

Part contact surfaces

-

Screws

replace

Stage

Tightening torque

1.

120 ±15 Nm

Tab. 27: Tightening instruction

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Tighten screw plug 6 according to the tightening instruction.

Connect electrical connection cable to heating flange 2.

Connect negative cable to battery.

If a battery master switch is present: Turn on battery master switch.

Installing the charging pressure line

Fig. 116: Removing the charging pressure line 1 2

External hex bolt Sealing ring

3

Pipeline with banjo fittings

Install sealing ring 2.

Install pipeline with banjo fittings 3.

Tighten external hex bolt 1.

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Exhaust aftertreatment assembly

5.9 Exhaust aftertreatment assembly 5.9.1 Checking the exhaust aftertreatment assembly for leaks and damage WARNING Production of ammonia gas when heating above 100 °C from reducing agent deposits.

Serious poisoning possible.

Before maintenance work on the exhaust aftertreatment 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. 117: Components to be checked 1 2 3

Profile clamp Profile clamp Urea solution injector

4 5 6

Bracket clip Profile clamp Strap clamp

Check the components for leaks. copyright © Liebherr-Components Colmar SAS 2019

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If components are leaking: Do not start the engine.

Replace components, see repair manual.

Check components for proper fastening.

If components are loose: Do not start the engine.

Tighten loose components. (For more information see: SCRonly, page 113) Check the components for damage.

If components are damaged: Do not start the engine.

Replace damaged components, see repair manual.

5.9.2 Checking the profile clamps SCRonly

5 7

1 6

2

3

4

4

7 8

Fig. 118: Tightening torques 1 2 3 4

Profile clamp Profile clamp Profile clamp Hinge bracket

5 6 7 8

Bracket clip Reducing agent injector Temperature sensor/pressure sensor NOx sensor 3/NH3 sensor

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Exhaust aftertreatment assembly

Number Part

Tightening torque

1

Profile clamp 1

23 ±2 Nm

2

Profile clamp 2

9 +2/ -1 Nm

3

Profile clamp 3

23 ±2 Nm

4

Hinge bracket 4

21 ±1 Nm

5

Bracket clip 5

23 ±2 Nm

6

Reducing agent injector 6

5 ±0.5 Nm

7

Temperature sensor Pressure sensor

35 ±5 Nm

8

NOx sensor 3/NH3 sensor 8

50 ±10 Nm

Tab. 28: Tightening torques Check components for tight fit.

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

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Maintenance Lubricants and operating fluids

5.10 Lubricants and operating fluids 5.10.1 Fill quantities Name

Quantity

Engine oil

108 l (1.5 l per filter)

Coolant (engine) 39 l AdBlue®

See documentation from the device manufacturer.

Tab. 29: Fill quantities (reference values)

5.10.2 Engine oil Liebherr products When using original Liebherr lubricant products, the longest possible change interval according to the maintenance schedule can be used.

Sulfur content in fuel in ppm

Without emission type approval up to Stage IIIB / Tier4i

10

Up to Stage IV / Tier 4

Stage V

100% (standard interval according to maintenance schedule)

15

100%

500

50%

2000

25%

5000

13%

Liebherr recommends the use of the following products

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

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

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

Third party products Note Engine oils used must correspond to the Liebherr specification LH-00-ENGLA. 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

Without emission type approval up to Stage Up to Stage IV / Tier 4 IIIB / Tier4i

10

Stage V

50%

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Sulfur content in fuel in ppm

Without emission type approval up to Stage Up to Stage IV / Tier 4 IIIB / Tier4i

15

50%

500

25%

2000

13%

5000

6%

Oil specification

LH-00-ENG

Stage V

LH-00-ENGLA

Tab. 31: Engine oil change intervals when using non-Liebherr products

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

Avoid combining different products.

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

Anticorrosive antifreeze agent Liebherr recommendation Type

Name

Premix ) Liebherr Antifreeze OS Mix A

Tab. 32: 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. 33: 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. 34: Minimum requirements for the quality

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5.10.4 Fuel Minimum requirement for the quality Approved diesel fuels according to DIN EN 590 and ASTM D975

Without emission type approval up to Stage IIIB / Tier4i

Maximum sulfur content in the fuel

Up to Stage IV / Stage V Tier 4

2000 ppm

Lubricity at 60 °C (HFRR) Minimum cetane number

15 ppm 460 m

10 ppm 400 m

45

Fuel purity for tank filling according to ISO 4406:

18/17/14

Tab. 35: Minimum requirement for diesel fuels Specification LH-00-FUEL Tab. 36: Minimum requirement for the quality

Reducing agent Approved reducing agent: – Reducing agent standardized according to ISO 22241 Specification LH-00-UREA Tab. 37: Minimum requirement for the quality for better results Designations: – AdBlue® in Europe – DEF (Diesel exhaust fluid) in the USA – AUS 32 (aqueous urea solution)

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6 Malfunctions

See Faults - Cause - Remedy table for engine problems and corrective measures. (For more information see: 6.1 Störungen - Ursache - Abhilfe, page 119) The engine control unit has an error memory. Error entries are stored in the error memory. The remedy for the errors is described in the device documentation.

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

6.1 Störungen - Ursache - Abhilfe Malfunction / error

Cause

Remedy

Starter dreht nicht durch.

Hauptsicherung defekt

Sicherung ersetzen.

Starter dreht nicht durch.

Batterieanschlüsse lose oder korrodiert

Lose Anschlüsse reinigen und festziehen.

Kontakte reinigen.

Starter dreht nicht durch.

Batteriespannung zu niedrig

Batterie laden oder ersetzen.

Starter dreht nicht durch.

Starterstromkreis unterbrochen

Liebherr-Kundendienst kontaktieren.

Starter dreht nicht durch.

Kontakte korrodiert

Kontakte reinigen.

Starter dreht nicht durch.

Starter defekt

Liebherr-Kundendienst kontaktieren.

Starter dreht langsam durch.

Batteriespannung zu niedrig

Batterie laden oder ersetzen.

Starter dreht langsam durch.

Batterieanschlüsse lose oder korrodiert

Lose Anschlüsse reinigen und festziehen.

Starter dreht langsam durch.

Außentemperatur zu niedrig

Maßnahmen für Winterbetrieb beachten.

Starter dreht langsam durch.

Motor unter Last

Aggregate vom Nebenabtrieb trennen.

Sicherstellen, dass Kraftschluss zwischen Motor und Kraftübertragung getrennt ist.

Motor bleibt unmittelbar nach Start stehen.

Kraftstoffbehälter leer

Motor bleibt unmittelbar nach Start stehen.

Kraftstoff-Feinfilter verstopft

Auftanken.

Kraftstoffsystem entlüften.

Kraftstoff-Feinfilter ersetzen.

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Störungen - Ursache - Abhilfe

Malfunction / error

Cause

Remedy

Motor bleibt unmittelbar nach Start stehen.

Kraftstoff-Vorfilter verstopft

Kraftstoff-Vorfilter ersetzen.

Motor bleibt unmittelbar nach Start stehen.

Kraftstoffleitung, Vorreiniger oder Sieb in Kraftstoffbehälter verstopft

Kraftstoffleitung, Vorreiniger oder Sieb in Kraftstoffbehälter reinigen.

Kraftstoffsystem entlüften.

Motor bleibt unmittelbar nach Start stehen.

Kraftstoff nicht kältefest

Kraftstoff-Vorfilter reinigen.

Kraftstoff-Feinfilter ersetzen.

Winterkraftstoff verwenden.

Motor bleibt unmittelbar nach Start stehen.

Außentemperatur zu niedrig

Maßnahmen für Winterbetrieb beachten.

Motor bleibt unmittelbar nach Start stehen.

Heizflansch defekt (bei kalten Temperaturen)

Heizflansch prüfen, wenn notwendig ersetzen.

Motor bleibt unmittelbar nach Start stehen.

Abgasstrang verschmutzt

Abgasstrang reinigen.

Motor bleibt unmittelbar nach Start stehen.

Motorbremsklappe geschlossen

Steuerung der Motorbremsklappe prüfen.

Liebherr-Kundendienst kontaktieren.

Motor startet schlecht.

Undichtheit oder zu geringer Druck im Kraftstoff-Niederdruck-Kreislauf

Dichtheitsprüfung (Sichtprüfung) durchführen.

Liebherr-Kundendienst kontaktieren.

Motor startet schlecht.

Motorkompression zu gering

Liebherr-Kundendienst kontaktieren.

Motor startet schlecht.

Heizflansch defekt (bei kalten Temperaturen)

Heizflansch prüfen, wenn notwendig ersetzen.

Motor startet schlecht.

Störung der Elektronik

Liebherr-Kundendienst kontaktieren.

Motor startet schlecht.

Raildruck zu niedrig

Rail auf Undichtheiten untersuchen.

Motor startet schlecht.

Luft in Kraftstoffsystem

Kraftstoffsystem entlüften.

Motor startet schlecht.

Luftfilter verstopft

Luftfilter auf Verschmutzung prüfen.

Motor startet schlecht.

Minderwertige Kraftstoffqualität

Ausschließlich von Liebherr empfohlenen Kraftstoff verwenden.

Motor startet schlecht.

Injektor defekt

Liebherr-Kundendienst kontaktieren.

Motor startet schlecht.

Ventilspiel nicht korrekt eingestellt

Ventilspiel prüfen. Bei Bedarf, Ventilspiel einstellen.

Motor stellt ungewollt ab.

Spannungsversorgung unterbrochen

Liebherr-Kundendienst kontaktieren.

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Malfunctions Störungen - Ursache - Abhilfe

Malfunction / error

Cause

Motor stellt ungewollt ab.

Undichtheit oder zu geringer Druck im Kraftstoff-Niederdruck-Kreislauf

Remedy Dichtheitsprüfung (Sichtprüfung) durchführen.

Von Liebherr-Kundendienst prüfen lassen.

Motor stellt ungewollt ab.

Störung der Elektronik

Liebherr-Kundendienst kontaktieren.

Motor stellt ungewollt ab.

Kraftstoffzufuhr nicht gewährleistet

Kraftstoffsystem prüfen.

Leistungsreduktion des Motors

Kraftstoffsystem defekt

Sichtprüfung durchführen.

Filter ersetzen.

Leistungsreduktion des Motors

Ladedruck zu gering

Schellen, Dichtungen, Schläuche und Luftfilter prüfen.

Leistungsreduktion des Motors

Ladelufttemperatur zu hoch

Ladeluftkühler, Lüfter und Umgebungstemperatur prüfen.

Leistungsreduktion des Motors

Kühlmitteltemperatur zu hoch

Kühler auf Verschmutzung prüfen.

Lüfter prüfen.

Thermostat prüfen.

Kühlmittelstand prüfen.

Leistungsreduktion des Motors

Kraftstofftemperatur zu hoch

Liebherr-Kundendienst kontaktieren.

Leistungsreduktion des Motors

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

Leistungsreduktion des Motors

Injektoren bleiben hängen oder zerstäuben nicht.

Liebherr-Kundendienst kontaktieren.

Leistungsreduktion des Motors

Motorkompression zu gering

Liebherr-Kundendienst kontaktieren.

Leistungsreduktion des Motors

Störung der Elektronik

Fehlerspeicher vom Motorsteuergerät auslesen.

Leistungsreduktion des Motors

Abgasnachbehandlungssystem verstopft

Liebherr-Kundendienst kontaktieren.

Leistungsreduktion des Motors

Ventilspiel nicht korrekt eingestellt

Ventilspiel prüfen. Bei Bedarf, Ventilspiel einstellen.

Leistungsreduktion des Motors

Zu wenig Reduktionsmittel in Reduktionsmittel-Tank

Reduktionsmittel auffüllen.

Ungenügende Motorbremsleistung

Motorbremsklappe ohne Funktion

Motorbremsklappe auf Funktion und Schäden prüfen.

Kein Defekt, Motorleistung automatisch reduziert.

Liebherr-Kundendienst kontaktieren.

Ungenügende Motorbremsleistung

Störung der Elektronik

Liebherr-Kundendienst kontaktieren.

Heißer Motor (nach Anzeige Kühlmitteltemperatur).

Zu wenig Kühlmittel

Nachfüllen.

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Störungen - Ursache - Abhilfe

Malfunction / error

Cause

Remedy

Heißer Motor (nach Anzeige Kühlmitteltemperatur).

Kühler innen verschmutzt oder verkalkt, Kühler außen verschmutzt

Kühler reinigen.

Heißer Motor (nach Anzeige Kühlmitteltemperatur).

Thermostat defekt

Thermostat prüfen.

Heißer Motor (nach Anzeige Kühlmitteltemperatur).

Kühlmitteltemperatur-Geber defekt

Kühler entkalken.

Bei Bedarf Thermostat ersetzen.

Kühlmitteltemperatur-Geber prüfen.

Bei Bedarf KühlmitteltemperaturGeber ersetzen.

Heißer Motor (nach Anzeige Kühlmitteltemperatur).

Lüfter zu geringe Drehzahl (ausschließlich hydrostatischer Lüfterantrieb)

Lüfterantrieb prüfen.

Heißer Motor (nach Anzeige Kühlmitteltemperatur).

Kühlmittelpumpe defekt

Kühlmittelpumpe ersetzen.

Heißer Motor (nach Anzeige Kühlmitteltemperatur).

Spannung Keilrippenreimen unzureichend

Spannung Keilrippenreimen prüfen. Bei Bedarf Spannrolle ersetzen.

Kontrollleuchte Ladestrom leuchtet bei laufendem Motor.

Keilrippenriemen gerissen

Keilrippenriemen ersetzen.

Kontrollleuchte Ladestrom leuchtet bei laufendem Motor.

Kabelverbindungen lose oder getrennt

Kabel befestigen oder ersetzen.

Kontrollleuchte Ladestrom leuchtet bei laufendem Motor.

Generator, Gleichrichter oder Regler defekt

Liebherr-Kundendienst kontaktieren.

Kontrollleuchte Ladestrom leuchtet bei laufendem Motor.

Prüfkreis offen

Liebherr-Kundendienst kontaktieren.

Motor raucht schwarz.

Abgasnachbehandlungssystem defekt

Liebherr-Kundendienst kontaktieren.

Motor raucht schwarz.

Einspritzanlage defekt

Liebherr-Kundendienst kontaktieren.

Motor raucht schwarz.

Ladeluftdruck-Sensor defekt

Ladeluftdruck-Sensor ersetzen.

Abgase sind blau.

Ölstand in Motor zu hoch

Ölstand korrigieren.

Abgase sind blau.

Motoröl verbrennt in Brennräumen.

Liebherr-Kundendienst kontaktieren.

Abgase sind blau.

Verdichterseitige Abdichtung am Abgasturbolader defekt

Liebherr-Kundendienst kontaktieren.

Abgase sind blau.

Abgasseitige Abdichtung an Abgasturbolader defekt

Liebherr-Kundendienst kontaktieren.

Abgase sind blau.

Kurbelgehäuseentlüftung defekt

Prüfen, bei Bedarf ersetzen.

Abgase sind blau.

Kolbenringe defekt

Liebherr-Kundendienst kontaktieren.

Abgase sind blau.

Ventilschaftdichtungen defekt

Liebherr-Kundendienst kontaktieren.

Abgase sind weiß.

Einspritzung verzögert

Liebherr-Kundendienst kontaktieren.

Bei Bedarf Lüfterantrieb ersetzen.

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Malfunctions Störungen - Ursache - Abhilfe

Malfunction / error

Cause

Remedy

Abgase sind weiß.

Heizflansch defekt (Temperatur < -10 °C)

Heizflansch prüfen. Bei Bedarf Heizflansch ersetzen.

Abgase sind weiß.

Kühlmittel in Brennraum

Liebherr-Kundendienst kontaktieren.

Motor nagelt.

Verbrennungsstörungen

Liebherr-Kundendienst kontaktieren.

Motor klopft.

Injektor beschädigt oder verkokt

Liebherr-Kundendienst kontaktieren.

Motor klopft.

Lagerschaden

Liebherr-Kundendienst kontaktieren.

Motor klopft.

Kolbenringe verschlissen, Kolbenringe gebrochen, Kolben gefressen

Liebherr-Kundendienst kontaktieren.

Abnormale Geräusche

Undichtheiten an Ansaugleitungen und Abgasleitungen verursachen Pfeifgeräusche.

Undichtheit beseitigen. Bei Bedarf Dichtung ersetzen.

Abnormale Geräusche

Fremdkörper in Verdichter oder Turbine

Liebherr-Kundendienst kontaktieren.

Abnormale Geräusche

Anstreifen des Turbinenrades oder Verdichterrades am Gehäuse

Liebherr-Kundendienst kontaktieren.

Abnormale Geräusche

Festgefressene Lager der rotierenden Teile

Liebherr-Kundendienst kontaktieren.

Schmieröldruck zu niedrig

Ölstand in Ölwanne zu niedrig

Ölstand korrigieren.

Schmieröldruck zu niedrig

Motoröl zu dünnflüssig

Öl ablassen. Öl einfüllen.

Ursache der Ölverdünnung feststellen und beheben.

Schmieröldruck zu niedrig

Öldruckgeber defekt

Motorölsystem prüfen.

Beschädigten Öldruckgeber ersetzen.

Schmieröldruck zu niedrig

Endregelventil defekt

Liebherr-Kundendienst kontaktieren.

Schmieröldruck zu niedrig

Endregelventil verschmutzt

Liebherr-Kundendienst kontaktieren.

Schmieröldruck zu niedrig

Lagerspiel infolge Abnützung zu groß oder Lagerschaden

Liebherr-Kundendienst kontaktieren.

Schmieröldruck zu niedrig

Ölpumpe defekt

Ölpumpe prüfen. Ölpumpe bei Bedarf ersetzen.

Schmieröldruck zu niedrig

Ölfilter verstopft

Ölfilter wechseln.

Schmieröldruck zu niedrig

Öldruck-Regelventil defekt

Liebherr-Kundendienst kontaktieren.

Motoröl in Kühlsystem

Ölkühler oder Ölkühlerplatte leckt

Liebherr-Kundendienst kontaktieren.

Kühlmittel in Motoröl

O-Ringe an Zylinderlaufbuchsen lecken

Liebherr-Kundendienst kontaktieren.

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Malfunctions

Operator's manual

Störungen - Ursache - Abhilfe

Malfunction / error

Cause

Kühlmittel in Motoröl

Ölkühler oder Ölkühlerplatte leckt

Remedy Liebherr-Kundendienst kontaktieren.

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7 Tools and devices

7.1 Tools 7.1.1 Special tool Graphic representation

Description

Assembly pin (viscous damper)

Required number

Identification number

2

tbd

Tab. 38: 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. 39: Locking agent Sealant Designation Identification number Quantity Loctite 5910 10354595

300 ml

Tab. 40: Sealant Lubricants Designation

Identification number Quantity

NBU 30 grease 10285708

1 kg

Motorex 14

10002552

850 g

Altemp QNB 50 10490569

80 g

Tab. 41: Lubricants

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Tools

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

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Tools and devices Devices

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

Leads to death or serious injuries.

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 127) Remove the gearbox or other attachments before lifting the engine.

Take safety instructions / warning signs from the operating instructions 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). 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. 120: Lifting the engine A

Transport device detail view

1

B

Front / rear view of two lateral transport devices

2

Tolerance for maximum deviation of motor axis Crankcase

See next page for continuation of the image legend

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Tools and devices

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Devices

C D

Side engine view Front / rear view of lateral transport device

3 4

E

Lifting traverse lifting point detail view

5

F

Take lifting traverse warning signs, lifting traverse operating instructions into account.

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

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

Chain suspension T-slide piece Attachment point sticker (see: fig. 122, page 129)

4 5

I-reception tube I-slide piece

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

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Tools and devices Devices

Fig. 122: Attachment point sticker

7.2.2 Lifting traverse with two-point-raising

Fig. 123: Lifting traverse with two-point-raising 1 2

I-slide piece I-reception tube

3

Chain suspension

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Tools and devices

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Devices

7.2.3 Engine assembly stand

Fig. 124: Engine assembly stand 1 2 3

Universal mount Engine assembly stand Height

4 5

Length Width

Engine assembly stand

10471324

10467805

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

Universal mount

10467810 2500 kg

Dimensions Width Length Height

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

Own weight

approx. 1250 kg

approx. 1100 kg

Tab. 42: Technical data

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Tools and devices Devices

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

Leads to death or serious injuries.

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 127) Remove the gearbox or other attachments before lifting the engine.

Take safety instructions / warning signs from the operating instructions 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).

Tightening instruction for M16x40 10.9 FLZN ring bolt Lubricant

-

Locking agent

Loctite 243

Part contact surfaces

-

Screws

Reusable

Stage

Tightening torque

1.

280 ±35 Nm

Tab. 43: Tightening instruction

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Devices

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8 Appendix

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

ISO 4014 ISO 4017 ISO 8765 ISO 8676

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

Values for an average coefficient of friction of

= 0.12

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

Nm

Strength class

ft/lb

Nm

8.8

ft/lb

Nm

10.9

ft/lb 12.9

M4

3

2

4

3

5

4

M5

6

4

8

6

10

7

M6

10

7

14

10

17

13

M7

16

12

23

17

27

20

M8

23

17

34

25

40

30

M10

46

34

68

50

79

58

M12

79

58

117

86

135

100

M14

125

92

185

136

215

159

M16

195

144

280

207

330

243

M18

280

207

390

288

460

339

M20

390

288

560

413

650

479

M22

530

391

750

553

880

649

M24

670

494

960

708

1120

826

M27

1000

738

1400

1033

1650

1217

M30

1350

996

1900

1401

2250

1660

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Appendix

Operator's manual

Tightening torques

Standard thread

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

M33

1850

1364

2600

1918

3000

2213

M36

2350

1733

3300

2434

3900

2876

M39

3000

2213

4300

3172

5100

3762

ft/lb

Nm

ft/lb

Tab. 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

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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:

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Appendix

Operator's manual

Tightening torques

Standard thread

Nm

ft/lb

Standard thread

Nm

ft/lb

M6x1

7

5

M 20 x 1.5

47

35

M8x1

7.5

6

M 22 x 1.5

57

42

M 8 x 1.5

7.5

6

M 24 x 1.5

68

50

M 10 x 1

15

11

M 26 x 1.5

75

55

M 10 x 1.25

15

11

M 27 x 2

87

64

M 12 x 1.5

20

15

M 30 x 1.5

115

85

M 14 x 1.5

27

20

M 30 x 2

115

85

M 16 x 1.5

37

27

M 33 x 2

120

89

M 18 x 1.5

40

30

M 36 x 1.5

155

114

M 36 x 2

155

114

M 52 x 1.5

380

280

M 38 x 1.5

171

126

M 52 x 2

380

280

M 39 x 2

215

159

M 56 x 2

430

317

M 42 x 1.5

240

177

M 60 x 2

510

376

M 42 x 2

240

177

M 64 x 2

570

420

M 45 x 1.5

270

199

M 65 x 2

620

457

M 45 x 2

270

199

M 48 x 1.5

300

221

M 48 x 2

300

221

Tab. 48: Tightening torques for locking screws and banjo bolts

8.1.3 Standard torques for metric flange connections

Fig. 127: Overview of flange connections

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Appendix Tightening torques

Note Tightening torques apply for mating material: Steel.

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

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

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

Thread Y

Form A with sealing ring

Form B with sealing edge

6

Form E with flat (ED) seal

Form F with oring

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

M 10 x 1.0

9

7

18

13

18

13

15

11

8

M 12 x 1.5

20

15

30

22

25

18

25

18

10

M 14 x 1.5

35

26

45

33

45

33

35

26

12

M 16 x 1.5

45

33

65

48

55

41

40

30

15

M 18 x 1.5

55

41

80

59

70

52

45

33

18

M 22 x 1.5

65

48

140

103

125

92

60

44

22

M 26 x 1.5

90

66

190

140

180

133

100

74

28

M 33 x 2.0

150

111

340

251

310

229

160

118

35

M 42 x 2.0

240

177

500

369

450

332

210

155

42

M 48 x 2.0

290

214

630

465

540

398

260

192

Tab. 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

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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

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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 (heavy) - 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 (heavy) - part 2

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

Thread Y Form A with sealing ring

Form B with sealing edge

Form E with flat (ED) seal

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

6

G 1/4A

35

26

55

41

40

30

8

G 1/4A

35

26

55

41

40

30

10

G 3/8A

45

33

90

66

80

59

12

G 3/8A

45

33

90

66

80

59

14

G 1/2A

65

48

150

111

115

85

16

G 1/2A

65

48

130

96

115

85

20

G 3/4A

90

66

270

199

180

133

25

G 1A

150

111

340

251

310

229

30

G 1 1/4A

240

177

540

398

450

332

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Tightening torques

Pipe diameter X

38

Thread Y Form A with sealing ring

G 1 1/2A

Form B with sealing edge

Form E with flat (ED) seal

Nm

ft/lb

Nm

ft/lb

Nm

ft/lb

290

214

700

516

540

398

Tab. 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

ft/lb

Form E with flat (ED) seal 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

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Fig. 128: 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. 129: Triple lock flange connections

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Tightening torques

Series

Pipe diameter X mm

Standard thread Z

inch

Nm

UN/UNF

ft/lb Steel

Nm

ft/lb

Stainless steel

4

6

1/4

7/17-20

15

11

30

22

5

8

5/16

1/2-20

20

15

40

30

6

10

3/8

9/16-18

30

22

60

44

8

12

1/2

3/4-16

60

44

115

85

10

14, 15, 16

5/8

7/8-14

75

55

145

107

12

18, 20

3/4

1 1/16-12

110

81

180

133

16

22

7/8

1 5/16-12

135

100

225

166

25

1

1 5/16-12

175

129

255

188

1 5/8-12

260

192

295

218

1 5/8-12

260

192

295

218

1 7/8-12

340

251

345

254

1 7/8-12

340

251

345

254

2 1/4-12

380

280

400

295

2 1/2-12

450

332

470

347

28 20

30, 32

1 1/4

35 24

38

28

42

32

50

1 1/2

2

Tab. 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. 130: 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

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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

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Supplemental Information USA

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

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

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

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

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

Liebherr’s Responsibilities:

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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Supplemental Information USA

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

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

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

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

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MODEL:

PIN (Prod. Id. No.):

NAME OF DEALER

NAME OF OWNER

SIGNATURE OF AUTHORIZED REPRESENTATIVE OF DEALER

SIGNATURE OF AUTHORIZED REPRESENTATIVE OF OWNER

CITY / STATE / ZIP CODE OF DEALER

CITY / STATE / ZIP CODE OF OWNER

-

DATE MACHINE PLACED INTO SERVICE Fig. 131

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

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

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

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

WARRANTED PARTS The emission-related parts (as equipped) that are warranted under this warranty for all Liebherr engines may include the following: – Fuel Injection System – Air Induction System – Turbocharger System – Charge Air Cooling System

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Supplemental Information USA

– – – – – – – – – – – –

Exhaust Gas Recirculation (EGR) System EGR Control System Exhaust Manifold Ignition System Diesel Particulate Filter System Diesel Oxidation Catalyst Fuel Additive Devices or Exhaust Aftertreatment Devices Selective Catalyst Reduction Reductant Containers Electronic Control Unit, Sensors, Solenoids, and Wiring Harnesses Emission Control Information Label Crankcase Ventilation Valves

OWNER’S WARRANTY RESPONSIBILITIES: As the off-road engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. Liebherr recommends that you retain all receipts covering maintenance of your off-road engine, but Liebherr cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

As the off-road engine owner, you should however be aware that Liebherr may deny warranty coverage if your off-road engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

Your engine is designed to operate on the fuel specified in your owner’s manual. Use of any other fuel may result in your engine no longer operating in compliance with California’s emissions requirements.

You are responsible for initiating the warranty process. The California Air Resources Board suggests that you present your off-road engine to Liebherr’s dealer as soon as a problem exists.

The warranty repairs should be completed by the dealer as expeditiously as possible.

If you have any question regarding your warranty rights and responsibilities, you should contact Liebherr at 1-877-806-1588.

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