Liebherr D934 A7 SCR D936 A7 SCR D946 A7 SCR Diesel Engine Operating Manual 10140787-00 – PDF

LIEBHERR Diesel engine D934 A7 SCR - D936 A7 SCR - D946 A7 SCR BAL: 10140787-00-en

Operating manual

en Dieselmotor D934 A7 D936 A7 D946 A7- SCR featuring exhaust gas after-treatment system SCR (selective catalytic reduction) From serial number 2012030001 / 2012040001

Document ID Order number: Issued: Version: Author:

10140787 01.01.2012 00 LMB / Department BE-MD3

Product ID Manufacturer: Type: Type no.: Serial no. from:

LIEBHERR MACHINES BULLE S.A. D934 A7 D936 A7 D946 A7 SCR featuring exhaust gas after-treatment system SCR (selective catalytic reduction) 2012030001 / 2012040001

Contact Address:

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

Machine data: Enter the following information on taking delivery. *You will find the information on the type plate of the machine. This will also be useful when you order spares.

* Engine ID number: ............................................................

* Year of construction: .............................

Commissioning date:

LMB/10140787/00/01.01.2012/en

.................. / ................. / .................

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D934 A7 D936 A7 D946 A7 SCR featuring exhaust gas after-treatment system SCR (selective catalytic reduction) / 2012030001 / 2012040001

Foreword

These operating instructions have been compiled for the user and for the maintenance personnel of the diesel engine.

The instructions include descriptions regarding: – Technical data – Safety requirements – Operation and servicing – Maintenance The operating manual is to be read thoroughly and referred to before initial start-up and at regular periods thereafter by each person contracted to carry out work with/on the diesel engine.

Tasks with or on the diesel engine include for example: – Operation, servicing, disposing of fuels and lubricants.

– Repair, including maintenance and inspection.

This simplifies training of the operator for his diesel engine and prevents malfunctions resulted from improper use.

Please understand that we do not recognise warranty claims submitted as a result of improper operation, insufficient maintenance, the utilisation of impermissible fuels or negligence of the safety guidelines.

LIEBHERR will declare all possible undertakings carried out by LIEBHERR and/or their dealers, such as guarantees, service orders, etc. null and void without advance notice, if spare parts other than original LIEBHERR spare parts or spare parts purchased by LIEBHERR are used for maintenance or repair.

It may be necessary to undertake maintenance tasks more regularly than is prescribed in the inspection plan when working in tougher conditions.

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Modifications, conditions and copyright: – Modifications of technical data, as regards information and illustrations within the documentation currently valid for the diesel engine, remain reserved.

– Conditions for warranty and liability of the general terms of trade for the LIEBHERR Company are not extended by the aforementioned details.

– Information and diagrams featured within this operating manual may not be reproduced or distributed, nor used for the purpose of the competition. All rights remain exclusively reserved in accordance with copyright laws.

D934 A7 D936 A7 D946 A7 SCR featuring exhaust gas after-treatment system SCR (selective catalytic reduction) / 2012030001 / 2012040001

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Foreword

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D934 A7 D936 A7 D946 A7 SCR featuring exhaust gas after-treatment system SCR (selective catalytic reduction) / 2012030001 / 2012040001

Contents

1

Product description

9

1.1

Technical description

9

1.1.1

Overview of assembly

9

1.1.2

Explanation of type description

11

1.1.3

Design features

14

1.1.4

Special equipment for the diesel engine

16

1.2

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2

Technical data

17

1.2.1

Diesel engine

17

1.2.2

Cylinder head, standard

17

1.2.3

Cylinder head with engine auxiliary brake system (ZBS)

18

1.2.4

Coolant pump D934

18

1.2.5

Coolant pump D936 / D946

18

1.2.6

Coolant thermostat

18

1.2.7

Generator

18

1.2.8

Starter

18

1.2.9

Flywheel housing

19

1.2.10 Air compressor Wabco 293 cm3

19

1.2.11 Air compressor Wabco 352 cm3

19

1.2.12 Air compressor Knorr 300 cm3

19

Notes on safety

21

2.1.1

21

Designation of warning information

2.2

General notes on safety

22

2.3

Use as directed

22

2.4

Notes on the prevention of crushing and burns

23

2.5

Notes on the prevention of fire and explosions

23

2.6

Observe safety precautions when starting

23

2.7

Measures for safe maintenance

24

2.8

Observe the safety precautions for diesel engines featuring electronic control units

25

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Contents

3

4

5

Safety and emergency run program for diesel engines featuring electronic control units

2.10 Special notes regarding tasks on the Common Rail System

26

2.11 Particularly hazardous

27

2.12 Disposing of fuels and lubricants

29

2.13 Exhaust gas after-treatment system (SCR)

29

Operation, Servicing

31

3.1

Control and operating elements

31

3.2

Operation

32

3.2.1

Preparations prior to initial start-up

32

3.2.2

Initial start-up / test run

32

3.2.3

Start the diesel engine.

33

3.2.4

Starting in frosty temperatures

34

3.2.5

Switching off the diesel engine.

34

3.2.6

Exhaust gas after-treatment system (SCR)

35

Malfunctions

45

4.1

45

Faults - Cause - Remedy

Maintenance

51

5.1

Maintenance and inspection chart

51

5.2

Filling amounts

54

5.2.1

54

5.3

Table for filling amounts

Fuels and lubricants

55

5.3.1

Handling fuels and lubricants

55

5.3.2

Environmental-protection guidelines

55

5.3.3

Disposing of used materials

55

5.3.4

Diesel fuels

55

5.3.5

Lube-oils for the diesel engine

56

5.3.6

Coolant for diesel engine

58

5.4

Special tools for maintenance tasks

62

5.5

Preparatory maintenance tasks

65

5.6

Maintenance tasks (daily), every 10 operating hours

66

5.6.1

Check the engine oil level

66

5.6.2

Visual inspection (leaks, contamination, damages)

67

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2.9

Contents

5.7

5.8

5.6.3

Check the coolant level

67

5.6.4

Checking / draining the water separator of the fuel prefilter

67

5.6.5

Check low-pressure display of the air filter

69

Maintenance tasks (weekly) every 50 operating hours

70

5.7.1

Drain water and sediment in the fuel tank

70

5.7.2

Cleaning the dust-discharge valve of the air filter

70

Maintenance tasks, every 500 operating hours

71

5.8.1

Check the flap of the diesel engine brake

71

5.8.2

Changing diesel engine oil and replacing the oil filter

71

5.8.3

Replacing the oil separator filter element

75

5.8.4

Checking and replacing the ribbed V-belt

76

5.8.5

Checking induction and exhaust gas system for sound condition and for leaks

78

Check the cooling and heating systems for sound condition and for leaks

78

Checking lubrication system and fuel system for leaks and for sound condition

79

5.8.8

Checking the batteries and cable connections

79

5.8.9

Checking the control unit mounting for sound condition

79

5.8.10 Checking sensors, actuators, cable fittings and plugs for sound condition

80

Maintenance tasks every 1000 operating hours

81

5.8.6 5.8.7

5.9

5.9.1

Checking the oil sump, engine mount and diesel engine brackets for secure seating

81

5.9.2

Checking and adjusting valve clearance

82

5.9.3

Replacing the fuel prefilter element

87

5.9.4

Replacing the fuel fine-filter

88

5.10 Maintenance tasks every 2000 operating hours 5.10.1 Checking anticorrosive / antifreeze concentration in the coolant

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5.11 Maintenance tasks every 3000 operating hours

90 90 94

5.11.1 Grease the flywheel starter ring gear

94

5.11.2 Replacing the coolant

94

5.12 Maintenance tasks every 4500 operating hours 5.12.1 Replacing the foam element and the filter element of the SCR urea pump 5.13 Maintenance tasks every 10000 operating hours 5.13.1 Replace the heater flange

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97 97 99 99

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Contents

6

5.14 Maintenance tasks as required

100

5.15 Check the heater flange

101

5.16 Bleeding the fuel system

102

5.17 Replacing the dry air filter main element

106

5.18 Replacing the dry air filter safety element

107

5.19 Transport and storage

108

5.19.1 Lifting gear

108

5.19.2 Storage up to 6 months

108

5.19.3 Storage for between 6 and 24 months

109

Supplemental Information USA 6.2.1 6.3

111

EPA/CARB Fuel label

111

Emission control warranty statement warranty rights and obligations

112

6.3.1

Manufacturer's warranty coverage

112

6.3.2

Owner's warranty responsibilities

112

6.3.3

Warranty coverage

113

6.3.4

Warranted parts

113

Index

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1 Product description

1.1 Technical description 1.1.1 Overview of assembly

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This section features a summary of the diesel engine including a description of the components represented.

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Product description Technical description

1 2 3 4 5 6

Visco-damper Water pump Automatic tension pulley Thermostat housing Throttle valve Heater flange

7 8 9 10 11 12

Cylinder head cover Air induction pipe Connecting line Intake manifold Starter Exhaust turbocharger

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13 14 15 16

Crankcase Oil sump Exhaust pipe Oil cooler

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Fig. 1: Components of diesel engine D936 A7 SCR / view from the left

Product description Technical description

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Fig. 2: Components of the diesel engine D936 A7 SCR / view from the right 1 2 3 4 5 6

Flywheel Flywheel housing Power take-off NA1 Power take-off NA2 Intake manifold Connecting line

7 8 9 10 11 12

Crankcase breather Fuel fine filter Oil filter Air-conditioning compressor Engine control unit Generator

13 14 15 16 17

Power take-off NA4 Oil intake Oil dipstick Power take-off NA3 SCR-Box

1.1.2 Explanation of type description Engine classification Description D

93

6

A7

SCR

D D934 A7 D936 A7 D946 A7 SCR featuring exhaust gas after-treatment system SCR (selective catalytic reduction) / 2012030001 / 2012040001

Engine type description Engine type: D = Diesel engine

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Product description Technical description

Description D

93

6

A7

SCR

93

Engine type description Bore: 122 mm (94 = 130 mm) / stroke: 150mm

6

Number of cylinders A7

Injection system: A7 = Common Rail SCR

Exhaust after-treatment system: SCR

Tab. 1

Diesel engine type identification plate The diesel engine identification plate is mounted on the right-hand side of the crankcase looking at the flywheel. A second identification plate on the air induction pipe.

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Fig. 3: Identification plate

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Product description Technical description

Diesel engine number

Fig. 4: Diesel engine number 1 2

Year Number of cylinders (03=4 cylinders, 04=6 cylinders)

3

Serial number

Engine control unit identification plate

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Fig. 5: Example of engine control unit identification plate 1 2 3 4 5

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Date of delivery 2D codebar Engine type Designation of control unit Engine identification number

6 7 8 9 10

Engine serial number Control unit identification number Update index Software version Control unit serial number

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Product description Technical description

Note

The information on the engine control unit identification plate corresponds with the condition at the time of delivery (from the Liebherr Machines Bulle factory). Depending on the software update in the field, it is possible that this information is no longer current. The updated information can be retrieved from the machine's display or read out from the Liebherr diagnosis and service tool, Sculi.

Tab. 2

Cylinder designation, rotational direction

Fig. 7: Cylinder designation / rotational direction Cylinder 1 is on the same side as the flywheel. The cylinder numbers, as well as the firing sequence, are cast onto the right-hand upper side of the crankcase, looking at the flywheel.

1.1.3 Design features Diesel engine design

Diesel engine characteristics A rugged basic design and largely-dimensioned size form the basis for optimum operating safety and long life-expectancy. Reduced fuel-consumption, as well as low noise and exhaust emissions due to a combustion process which is specially adapted to suit the high requirements. Reduced maintenance to easily accessible components and a multitude of mounting options for special equipment contribute to optimum overall efficiency of the diesel engine.

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Water-cooled 4- and 6- cylinder in-line diesel engine with Common Rail (CR) direct injection, exhaust turbocharging and intercooling.

Product description Technical description

Engine The 4-cylinder diesel engines feature a steel crankshaft with 5 bearing points and 2 counterbalancing shafts / the 6-cylinder diesel engines feature a steel crankshaft with 7 bearing points and inductive hardened running surfaces. A torsion damper is mounted on the crankshaft on the same side as the fan. Forge pressed, diagonallysectioned connecting rod, transmission bearing in lead bronze-triplex-friction bearings or sputter bearing. Three ring piston made of steel alloy featuring ring inserts and combustion recess in the piston crown. Replaceable, wet cylinder liners.

Crankcase Crankcase designed as one unit made of alloyed cast iron. 4-valve individual cylinder heads with swirl duct, as well as replaceable valve seat rings and valve guides. Flywheel housing, front-mounted aggregate carrier and oil sump mounted on the underside encase the diesel engine.

Drive control Two intake valves and exhaust valves respectively per cylinder suspended in the cylinder head. Actuated via steel camshaft with 5 or 7 bearings via roller tappet, push rod and rocker arm. Drive of the camshaft, fuel delivery pump, lube oil pump, air compressor and auxiliary hydraulic pumps from the crankshaft via nitrified gears on the same side as the flywheel, and water pump on the same side as the aggregate carrier.

Lubrication Forced-feed lubrication with gear pump for crankshaft bearing, connecting rod bearing and camshaft bearing, as well as small end bush and rocker arm. Oil filtering via two replaceable cartridge filters in the main flow. Accessories such as water pump, turbocharger, power take-offs, fuel delivery pump and air compressor are connected to the diesel engine lube oil circuit. The oil cooler is integrated in the cooling water circuit.

Cooling Thermostatic-regulated liquid cooling with coolant pump. Individual supply of each cylinder unit via cast distributor ducts in the crankcase. Piston cooling via cooling duct from the lube oil circuit of the diesel engine.

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Injection system High-pressure pump with flow control, supplied from a flange-mounted fuel transfer pump. Furl filter, high-pressure accumulator, CR-injectors with 8 blind hole nozzles.

Electronic diesel engine regulation The electronic diesel engine controller (EDC) serves to regulate the speed, injection begin and torque of LIEBHERR diesel engines. The EDC is comprised essentially of sensors, an injection system and the engine control unit. Devices located on the same side as the diesel engine and on the same side as the vehicle are connected to the engine control unit via cable harnesses.

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Product description Technical description

Electronic sensors on the engine side Boost pressure sensor, fuel pressure sensor, oil pressure sensor, temperature sensor for refrigerant, charge air and speed sensors are interfaces for external monitoring and control functions. The individual functions and error reports are described in the respective user documentation.

Mounting options for pumps The mounting of hydraulic pumps is possible on up to four power take-offs of the diesel engine.

1.1.4 Special equipment for the diesel engine Diesel engine brake and auxiliary brake system The diesel engine exhaust brake flap is installed in the exhaust pipe leading from the exhaust turbocharger to the muffler/exhaust after-treatment system. It is actuated by a cylinder charged with compressed air, and the engine braking action is generated via closing of the exhaust gas brake flap. A diesel engine auxiliary brake system (ZBS) has been installed in addition to the exhaust gas brake flap to increase braking action. The ZBS thus increases the engine braking action by ensuring that a gap in the exhaust valves remains open during the engine braking procedure.

Air compressor The air compressor is flange-mounted to a power take-off integrated on the flywheel housing. Cooling and lubrication of the air compressor is connected to the respective circuits of the diesel engine.

Air-conditioning compressor The air-conditioning compressor can be mounted directly onto the diesel engine and powered via a magnetic clutch featuring a ribbed V-belt. When the air-conditioning is switched on, the magnetic clutch is active and the compressor is working.

Cold start package

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The interfaces for the retrofitting of preheating devices, e.g. for coolant, fuel and diesel engine oil, are already integrated.

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Product description Technical data

1.2 Technical data 1.2.1 Diesel engine

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Description

Unit Value

Design

In-line diesel engine

Number of cylinders (D934)

4

Firing sequence

1–3–4–2

Number of cylinders (D936/D946)

6

Firing sequence

1–5–3–6–2–4

Borehole (D934/D936)

mm 122

Borehole (D946)

mm 130

Stroke

mm 150

Displacement (D934)

l 7,0

Displacement (D936)

l 10,5

Displacement (D946)

l 11,95

Compression ratio

17,4:1

Rotational direction of diesel engine (looking at the flywheel)

to the left

Performance group

LG1 to LG5

Power rating in accordance with

See identification plate

Nominal output

See identification plate

Nominal speed

See identification plate

Emission standards

See identification plate

D934 diesel engine weight (without water, without oil)

kg 870

D936/D946 diesel engine weight (without water, without oil)

kg 1210

1.2.2 Cylinder head, standard Description

Unit Value

Valve clearance intake cold

See identification plate

Valve clearance outlet cold

See identification plate

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Product description Technical data

1.2.3 Cylinder head with engine auxiliary brake system (ZBS) Description

Unit Value

Valve clearance intake cold

See identification plate

Valve clearance exhaust valve fitting / rocker arm cold

See identification plate

Valve clearance exhaust valve fitting / retainer cold

See identification plate

1.2.4 Coolant pump D934 Description

Unit Value

Flow rate (with a nominal speed of 1800 rpm and a counterpressure of 0,6 bar)

l/min 330

1.2.5 Coolant pump D936 / D946 Description

Unit Value

Flow rate (at a nominal speed of 1800 / 2000 rpm and counterpressure of 0.6 bar)

l/min 410 / 450

1.2.6 Coolant thermostat Description

Unit Value

Opening begin

°C 82

Completely opened

°C 92

1.2.7 Generator Unit Value

Voltage

V 28

Amperage type 1

A 100

Amperage type 2

A 110

1.2.8 Starter Description

Unit Value

Voltage

V 24

Output

kW 7.8

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Description

Product description Technical data

1.2.9 Flywheel housing Description

Unit Value

Connection

SAE 1 / SAE 2

1.2.10 Air compressor Wabco 293 cm

3

Description

Unit Value

Flow rate at a nominal speed of 1800 / 1900 rpm and 8 bar

l/min 430 / 443

gear transmission ratio

1 : 1,389

Water-cooled

Yes

1.2.11 Air compressor Wabco 352 cm

3

Description

Unit Value

Flow rate at a nominal speed of 2000 rpm and 8 bar

l/min 620

gear transmission ratio

1 : 1,389

Water-cooled

Yes

1.2.12 Air compressor Knorr 300 cm

3

Description

Unit Value

Flow rate at a nominal speed of 1800 / 2000 rpm and 8 bar

l/min 420 / 460 1 : 1,389

Water-cooled

Yes

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gear transmission ratio

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Product description

LMB/10140787/00/01.01.2012/en

Technical data

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2 Notes on safety

Working on the diesel engine is extremely hazardous to user, machine operator or maintenance technician. Dangers and accidents can be avoided if the various notes on safety are frequently read and adhered to.

This applies in particular for personnel carrying out maintenance tasks opportunely on the diesel engine.

Conscientious adherence of the safety guidelines, specified as follows, will guarantee the safety of yourself and others, as well as safeguarding against damage to the diesel engine.

All necessary safety precautions relevant to the description of tasks which could cause injury to personnel, or damage to the diesel engine, are described in this book.

2.1.1 Designation of warning information This is a warning sign. It warns against potential risks of injury. All measures stipulated for this warning sign must be adhered to if injuries and fatalities are to be prevented.

Tab. 3

LMB/10140787/00/01.01.2012/en

The warning sign is always displayed in correlation with the signal words DANGER WARNING ATTENTION DANGER

signifies an immediately dangerous situation which could result in fatalities or serious injury if it is not prevented.

WARNING

signifies a dangerous situation which could result in fatalities or serious injury if it is not prevented.

ATTENTION

signifies a dangerous situation which could result in minor or significant injury if it is not prevented.

CAUTION

signifies a dangerous situation which could result in material damage if it is not prevented.

Tab. 4

Further designations Note

signifies useful notes and tips.

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Notes on safety Use as directed

Additional rules and regulations Observation of these points does not exempt you from the adherence of additional rules and regulations!

2.2 General notes on safety 1.

2.

3.

4.

5.

6.

Familiarise yourself with the operating instructions prior to starting up the machine.

Make sure that you possess, have read, and have understood any additional instructions relevant to the machine's optional features.

Only expressly authorised personnel may perform operation, maintenance or repair of the machine.

Observe the legal, permissible minimum age!

Employ only trained or instructed personnel and allocate definitive responsibility for personnel regarding operation, setting up, maintenance and repair.

Personnel who are still undergoing training, or are involved with a general apprenticeship, should only be allowed to work on the diesel engine while under constant supervision of an experienced person.

Ensure regularly that personnel are conscientious of safety and dangers while working, and are observing the operating instructions.

Always wear safety clothing when working on the diesel engine.

The wearing of rings, wrist watches, ties, scarves, open jackets, loose fitting clothes, etc. is not permitted. There is risk of injury from getting caught up in or dragged into machinery, for example.

1.

2.

3.

This diesel engine has been designed exclusively for the intended use defined by the manufacturer and stipulated in the scope of delivery (use as directed): Any other form of use is not considered use as directed. The manufacturer can not be held responsible for any damage which occurs as a result. The user bears full responsibility.

Adherence to the conditions of operation, maintenance and repair stipulated by the manufacturer is also considered use as directed. The diesel engine may only be operated, maintained and repaired by personnel who are familiar with the diesel engine and who are aware of the dangers.

The manufacturer does not bear responsibility for any material damage or injury to persons which occurs as a result of unauthorised modifications to the diesel engine. Likewise, manipulation of the injection system and servo system could influence output and exhaust characteristics of the diesel engine, whereby compliance of the legal environmental regulations can no longer be guaranteed.

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2.3 Use as directed

Notes on safety Observe safety precautions when starting

2.4 Notes on the prevention of crushing and burns 1.

2.

3.

4.

5.

6.

Do not use any lifting materials, such as ropes or chains, which are damaged or do not feature sufficient lift capacity.

Always wear industrial gloves when handling wire cables.

Ensure that no objects come into contact with the fan while the diesel engine is running.

Objects which fall into, or protrude into, the fan will be flung back out or destroyed, and could cause damage to the fan.

When verging on operating temperature, the diesel engine's cooling system is hot and under pressure.

Avoid any contact with parts carrying cooling water.

Risk of burns!

Only check the level of the cooling water if the sealing cap of the expansion tank has cooled sufficiently that it can be touched.

Open the cap carefully to relieve any excess pressure.

The diesel engine oil is extremely hot when verging on operating temperature.

Avoid skin contact with hot oil or parts carrying oil.

Always wear protective glasses and industrial gloves when working on the battery.

Avoid sparks and naked flames.

2.5 Notes on the prevention of fire and explosions 1.

2.

3.

4.

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5.

6.

The diesel engine must be switched off when refuelling.

Switch off any other additionally installed heating.

Do not smoke and avoid naked flames in the area where batteries are being recharged and when refuelling.

Always start up the diesel engine in accordance with the guidelines stipulated in the operating instructions.

Check the electrical system.

Remedy all faults, such as loose connections and worn cables, immediately.

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

Remedy leaks and replace damaged components immediately.

2.6 Observe safety precautions when starting 1.

2.

3.

D934 A7 D936 A7 D946 A7 SCR featuring exhaust gas after-treatment system SCR (selective catalytic reduction) / 2012030001 / 2012040001

Unless otherwise specified, always start up the diesel engine in accordance with the guidelines stipulated in the operating instructions.

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

Only allow the diesel engine to run in enclosed areas if sufficient ventilation has been provided.

If necessary, open doors and windows to guarantee a sufficient supply of fresh air.

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Notes on safety Measures for safe maintenance

2.7 Measures for safe maintenance

2.

3.

4.

5.

6.

7.

8.

9.

Do not carry out any maintenance or repair tasks with which you are not familiar.

Observe all deadlines for recurring checks or inspections which have been prescribed or are specified in the operating instructions.

To carry out servicing measures, it is absolutely imperative that factory equipment appropriate for the respective task is used.

The tasks to be carried out, as well as the personnel who must or may perform these tasks, are clearly defined in the listing at the end of these operating instructions.

Only those tasks characterised with „by maintenance personnel” in the operating and maintenance instructions may be performed by the machine operator or the maintenance personnel. All other tasks may only be carried out by authorised personnel who have undergone the appropriate training.

Spare parts must comply with the technical requirements specified by the manufacturer. This can always be guaranteed with original spare parts.

Always wear protective clothing when carrying out maintenance tasks.

Unless otherwise specified in these operating instructions, all maintenance tasks to the diesel engine must be carried out on firm, even ground with the diesel engine switched off.

When carrying out maintenance and repair tasks, tighten the loosened screw connections with the prescribed tightening torque.

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

Do not use any flammable liquids for cleaning the diesel engine.

Before cleaning the machine with water, steam jet (high-pressure cleaner) or other cleaning agents, seal or cover all openings into which water/steam/ cleaning agents should not be allowed to penetrate due to reasons of safety or functionality.

The crankcase ventilation, electronics box, starter, generator and exhaust gas after-treatment system are at particular risk.

Additional tasks: • After cleaning, remove the covers or bondings completely.

• After cleaning, examine all fuel lines, diesel engine oil lines and engine oil lines for leaks, loose connections, points of wear and damages.

• Remedy any determined faults immediately.

10. Observe the safety guidelines valid for the product when handling oils, greases and other chemical substances.

11. Ensure that fuels and consumables, as well as replacement parts, are disposed of in a safe and environmentally-friendly manner.

12. Observe caution when handling hot fuels and consumables (danger of burning and scalding).

13. Always wear gloves when searching for leaks. A fine jet of liquid, when pressurised, could penetrate the skin.

14. Shut down the diesel engine before loosening oil lines.

15. Combustion engines may only be operated in sufficiently ventilated areas.

Ensure sufficient ventilation before initiating operation in enclosed areas.

Observe the valid guidelines for the respective jobsite.

16. Do not try to lift heavy parts. Suitable lifting gear featuring sufficient lift capacity must be used for these tasks.

Procedure:

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1.

Notes on safety Observe the safety precautions for diesel engines featuring electronic control units

• Tighten and secure individual parts and larger assemblies carefully to the lifting gears when replacing heavy parts, to eliminate any hazardous situations.

• Only use suitable and technically sound hoists, as well as load carrying equipment featuring sufficient lift capacity.

It is prohibited to remain or work beneath suspended loads.

17. Do not use ropes which are damaged, or do not feature sufficient lift capacity.

Always wear industrial gloves when handling wire cables.

18. Tasks to electrical equipment on the machine may only be carried out by an electrical specialist or by trained personnel under the supervision and instruction of an electrical specialist in compliance with the electrotechnical regulations.

19. Disconnect the battery when working on the electrical system and also remove the plug from the control unit if electric welding is to be carried out on the machine. Always disconnect the negative terminal first and reconnect last.

2.8 Observe the safety precautions for diesel engines featuring electronic control units

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1.

2.

3.

4.

Only start up the diesel engine with the batteries securely connected.

Do not disconnect batteries while the diesel engine is running.

The diesel engine may only ever be started with the control unit connected.

Do not use a fast charger to start the diesel engines. Only use jump leads with separate batteries.

5. The battery terminal clips must be disconnected for fast charging of the batteries. Refer to the operating instructions of the fast charger.

6. When carrying out welding work, the batteries must be disconnected and both cables (positive and negative) fastened securely with one another. Furthermore, the connecting plugs must be disconnected for all control units.

7. Connections of the control units may only be connected or disconnected with the electrical system switched off. Tighten the fastening screws of the interface plugs with the prescribed tightening torque.

8. Incorrect polarity of the control unit's voltage or supply voltage (e.g. via incorrect polarity of the batteries) can lead to ruination of the control units.

9. Tighten the connections to the injection system with the prescribed tightening torque.

10. If temperatures exceeding 80°C (e.g. drying kilns) are anticipated, the control units must be removed.

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

12. Neither sensors nor actuators may be connected individually to, or between, external voltage sources for inspection or test purposes, but rather always with the electronic control unit, otherwise there is a risk of the diesel engine malfunctioning or even becoming ruined.

13. The electronic control unit is only sufficiently protected against dust and water if the mating connector is mounted and attached. If no mating connectors have been attached, the control unit must be sufficiently protected against dust and water.

14. Telephones and radio equipment which are not connected to an external aerial could lead to functional failure of the vehicle's electronics, and thus jeopardise operational safety of the diesel engine.

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Notes on safety Special notes regarding tasks on the Common Rail System

2.9 Safety and emergency run program for diesel engines featuring electronic control units 1.

The diesel engine features an electronic regulating system, which monitors the diesel engine as well as the electronic regulating system itself (self-diagnosis).

As soon as a fault is detected, one of the following measures is implemented automatically following evaluation of the respective fault: • Issue of an error report featuring error code.

• The error code is issued directly via a display in conjunction with the vehicle diagnosis system.

• Changeover to suitable back-up function for further, however limited, operation of the diesel engine (e.g. constant emergency-run speed).

Have all faults remedied immediately by the respective LIEBHERR aftersales service.

1.

2.

3.

4.

With the diesel engine running, the lines are under a constant fuel pressure of up to 2200 bar.

• Never loosen the threaded connections on the fuel high-pressure side of the Common Rail System while the diesel engine is running.

Any fuel which escapes while under pressure can penetrate human skin, and thus cause serious injury. There is a risk of conflagrations due to misting of the fuel.

• After the diesel engine has been shut down, wait for at least another minute to give pressure in the Rail system time to dissipate.

• Do not remain in direct proximity of the diesel engine while the diesel engine is running.

• Persons with pacemakers should not approach within 20 cm of the running diesel engine.

• Do not touch voltage-carrying parts on the electrical connection of the injectors while the diesel engine is running.

State-of-the-art components for the diesel injection nowadays are made of high-precision parts which are subjected to extreme stresses. Due to this highprecision technology, utmost cleanliness must be guaranteed whenever tasks on the fuel system are undertaken.

Dirt particles exceeding 0.2 mm in size are enough to cause the failure of components.

It is absolutely imperative, therefore, that the following prescribed measures are adhered to before commencing any tasks: • Before commencing any tasks on the pure side of the fuel system, the diesel engine and the diesel engine compartment must be cleaned (steamjet cleaning), ensure that the fuel system is closed.

• Carry out a visual inspection of the fuel system for leaks or damages.

• Do not spray directly onto electrical components with the steam jet cleaner, mount covers wherever necessary.

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2.10 Special notes regarding tasks on the Common Rail System

Notes on safety Particularly hazardous

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5.

• Place the diesel engine in a clean area within the workshop where no work is being carried out which may cause dust to rise (grinding and welding work, repairs to brakes, inspecting brakes and lines etc.).

• Avoid disturbing the air (possible raising of dust by starting the diesel engine, aeration or heating of the workshop or as a result of draughts etc.).

• The area around the closed fuel system is to be cleaned with compressed air and dried .

• Remove loose dirt particles such as flakes of paint and insulating paper using suitable suction equipment (industrial vacuum cleaner).

• Hang a new, and clean cover sheet over areas of the diesel engine compartment which may be prone to releasing dirt particles.

• Before commencing the disassembly work, wash your hands and put on clean overalls.

It is imperative that the following prescribed measures are adhered to when carrying out work: • The utilisation of compressed air for cleaning is not permissible after opening the fuel system on the pure side.

• Loose dirt is to be removed during the assembly procedure using suitable suction equipment (industrial vacuum cleaner).

• Only lint-free cleaning cloths may be used on the fuel system.

• Tools and working appliances are to be cleaned before commencing work.

• Only tools which do not indicate any damage (cracks in the chrome coating) may be used.

• When removing and installing components, do not use materials such as towels, cardboard or wood, as these materials could release particles and fibres.

• Should flakes of paint become released when loosening connections (possibly caused by excessive painting), these flakes of paint must be carefully removed before definitively disconnecting the fitting.

• The open connection ports from all removed parts from the clean side of the fuel system are to be sealed immediately using appropriate sealing caps.

• This sealing material must remain in its dustproof packaging up to the point of utilisation and is to be disposed of immediately following initial use.

• The components are then to be stored carefully in a clean, sealed container.

• Never apply used cleaning agents or test fluids to these components.

• New parts may only be removed from their original packaging immediately before use.

• Work on removed components may only be carried out in a workplace specifically provided for this purpose.

• Should removed parts require posting, always use the original packaging from the new parts.

2.11 Particularly hazardous 1.

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Risk of injury as a result of moving parts Rotating parts and/or parts which are moved linearly can cause serious injuries.

• Do not reach into moving parts during operation and do not handle moving components.

• Do not open covers during operation.

• Observe the after-run time: Ensure before opening the covers that all parts have stopped moving.

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Notes on safety

2.

3.

4.

5.

6.

7.

8.

9.

• Wear close-fitting protective clothing when working within the danger area.

Risk of fatalities as a result of falling loads Loads could fall during the carrying out of lifting procedures. This could cause serious injury or even death.

• Only use the transport devices for transport of the engine, and do not use any other accessories.

• Diagonal pull is not permissible, and a suspension device must therefore be used.

Risk of conflagrations as a result of easily flammable materials Easily flammable materials, liquids or gases could burst into flames and cause serious or even fatal injuries.

• Do not smoke within the danger area or the surrounding areas. Refrain from handling naked flames or ignition sources.

• Always ensure that fire extinguishers are on-hand.

• Report any suspicious materials, liquids or gases immediately to the persons responsible.

• In cases of fire, stop work immediately. Exit the danger area until the allclear is given.

Risk of injury as a result of hazardous refrigerants Refrigerants contain hazardous substances. Contact with these substances can lead to serious poisoning, allergies, skin inflammation and damage to the eyes.

• Refer to the manufacturer's notes on safety.

• When handling refrigerants, always wear protective working clothing, chemical-resistant industrial gloves and protective glasses.

• Avoid spillages and misting.

Risk of burns as a result of hot fuels Fuels can attain high temperatures during operation and could cause burns upon contact with skin.

• Always check the temperature of fuels prior to handling. If necessary, allow to cool.

Risk of burns as a result of hot surfaces Contact with hot components could cause burns.

• For all work in immediate proximity to hot components, it is essential that protective working clothing and industrial gloves are worn.

• Ensure prior to commencing any work that all components have cooled to ambient temperature.

Loss of hearing resulting from noise Noise levels generated within the working area can cause serious damage to hearing.

• It is essential that hearing protection is worn during operation • Only remain within the danger area for as long as is absolutely necessary Risk of injury on edges and corners Sharp edges and pointed corners can cause skin abrasions and cuts.

• Ensure the utmost of care when working in close proximity to sharp edges and pointed corners.

• If in doubt, wear industrial gloves Risk of stumbling over dirt and objects left lying around Contamination and objects left lying around create situations of slipping and stumbling and could cause serious injuries.

• Always keep the working area clean and tidy.

• Always remove objects which are no longer required.

• Mark any hazardous areas in which persons are susceptible to stumbling with black and yellow cordoning tape.

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Particularly hazardous

Notes on safety Exhaust gas after-treatment system (SCR)

2.12 Disposing of fuels and lubricants 1.

2.

3.

4.

Ensure when handling fuels and lubricants, that no substances are spilled or poured onto the earth, into drainage systems or into bodies of water.

Different fuels and lubricants are to be collected and disposed of in separate containers.

Use sealed containers for draining fuels and lubricants. Under no circumstances should containers for food or drinks be used as the liquids could be drunk inadvertently.

Before recycling or disposing of waste products, enquire about the correct method at the appropriate environmental or recycling centre. Incorrect disposal of waste products can harm the environment and the ecology.

2.13 Exhaust gas after-treatment system (SCR) NOTICE In the event of water, steam or other cleaning agents penetrating the SCR-module!

The layer of substrate begins flaking.

NOx sensor faulty. u Cover all covers prior to commencing cleaning. u Ensure that no liquids or dirt penetrate the pipe end opening of the SCRmodule.

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u Allow the SCR-system to cool prior to cleaning (surface temperature < 50°C.

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Notes on safety

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Exhaust gas after-treatment system (SCR)

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3 Operation, Servicing

3.1 Control and operating elements The control elements and operating elements are integral parts of the machine and are described in the documentation of the manufacturer.

LMB/10140787/00/01.01.2012/en

Data pertaining to oil pressure, coolant temperature, speed, operating hours and service code, for example, are transferred to the machine via the electronic interface on the diesel engine for operation and regulation of the diesel engine.

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Operation, Servicing Operation

3.2 Operation 3.2.1 Preparations prior to initial start-up Brand new diesel engines are delivered from the factory already filled with the oil required for initial start-up. As a rule, replacement engines and engines which have undergone a general overhaul are delivered without fuel.

The high-grade oils used for initial start-up are ideally suited for the break-in process and allow the first oil-change to be carried out at the normal oil-change intervals.

For filling amounts, see the chapter “Filling amounts”.

For quality, see the chapter “Fuels and lubricants”.

Filling in fuels The following fuels are to be filled in prior to initial start up: – Diesel engine oil For suitable lube oils for the diesel engine, see the chapter “Fuel and lubricants”.

– Coolant For coolant composition, see the chapter “Fuel and lubricants”.

– Diesel fuel Use summer fuel or winter fuel in accordance with the season.

Diesel fuels must comply with the permissible fuel specifications, see the chapter “Fuel and lubricants”.

– Reducing agent (water urea solution) For suitable reducing agents, see the chapter “Exhaust gas after-treatment (SCR)”.

WARNING Naked flames!

Fire and explosion. u Do not smoke and avoid naked flames when refuelling. u Always shut down the diesel engine before refuelling.

After filling in fuel, perform the following tasks:

u Check the batteries (for correct procedure, refer to the documentation of the machine manufacturer). u Bleed the fuel system (for correct procedure, see the chapter “Maintenance”).

3.2.2 Initial start-up / test run Test run u Start the diesel engine. u Check the oil pressure gauge immediately after starting the diesel engine.

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u Lubricate the starter ring gear with grease (for correct procedure, see the chapter “Maintenance”).

Operation, Servicing Operation

Troubleshooting No oil pressure has been attained within 5 seconds? u Switch off diesel engine immediately. u Determine and remedy the cause. u Allow the diesel engine speed to increase gradually to 3/4 of the permissible maximum speed, until operating temperature has been reached.

NOTICE Impermissible loading of the diesel engine when still cold!

Damage to the diesel engine. u Allow the diesel engine to run warm until operating temperature is attained. u Run the diesel engine warm. w Coolant temperature > 60°C

Tasks to be performed following the test run It must be ensured that: q The diesel engine has been shut down. u Check the coolant level (for correct procedure, see the chapter “Maintenance”). u Check the diesel engine oil level (for correct procedure, see the chapter “Maintenance”). u Inspect the diesel engine for leaks (for correct procedure, see the chapter “Maintenance”).

3.2.3 Start the diesel engine.

Ensure that sufficient fuel has been filled. u Start the diesel engine in idle using the using the ignition key or starter button.

Troubleshooting The diesel engine will not start? u Wait for 1 minute.

If the diesel engine does not turn over after three start attempts: u Determine and remedy the cause.

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u Check the oil pressure gauge immediately after starting the diesel engine.

Troubleshooting No oil pressure has been attained within 5 seconds? u Switch off diesel engine immediately. u Determine and remedy the cause.

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Operation, Servicing Operation

NOTICE Impermissible loading of the diesel engine when still cold!

Damage to the diesel engine. u Allow the diesel engine to run warm until operating temperature is attained. u Run the diesel engine warm. w Coolant temperature > 60°C

3.2.4 Starting in frosty temperatures

Fig. 13: Winter operation The following precautionary measures will improve starting behaviour at low temperatures.

Precautionary measures: – Check the charge of the battery.

– Recharge the battery as necessary.

– Use diesel fuel with sufficient flow properties (see the chapter Fuel and lubricants under Diesel fuels at lower temperatures).

– Preheat the induction air (see documentation of the machine manufacturer).

WARNING Utilisation of ether-based starting aids!

Risk of explosion. u Do not use ether-based starting aids.

u Allow the diesel engine to run warm until operating temperature is attained.

3.2.5 Switching off the diesel engine.

WARNING Shutting down the diesel engine at full load speed! (exhaust turbocharger continues running for a short while without oil supply).

Risk of damage to the diesel engine. u Do not shut down the diesel engine from full load speed.

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NOTICE Impermissible loading of the diesel engine when still cold!

Damage to the diesel engine.

Operation, Servicing Operation

u Reduce the diesel engine speed to idle. u Allow the diesel engine to continue running briefly, approx. 10 to 15 seconds, without load in idle. u Switch off diesel engine.

3.2.6 Exhaust gas after-treatment system (SCR)

Fig. 14: Simple schematic representation of the SCR-system The SCR exhaust gas after-treatment (selective catalytic reduction) denotes a technique for the transformation or reduction of nitric oxides (NOx) in the exhaust gas, by adding a reduction agent (water urea solution), in nitrogen (N2) and water (H2O).

Reducing agent Labels: – AdBlue® in Europe – DEF (Diesel exhaust fluid) in the USA NOTICE Operation without reducing agent!

Legally prescribed exhaust gas limit values are not observed.

Users are liable for prosecution.

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u Operating the system with reducing agent. u Fill in the reducing agent in good time.

Specification The reducing agent must comply with the specifications listed as follows. Specifications: – DIN 70 070 – ISO 22241

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Operation, Servicing Operation

Utilisation / handling CAUTION Reducing agents can cause injury to the eyes and allergic skin reactions. u Avoid skin contact with reducing agents. u Refer to the manufacturer's instructions.

Note In the event that reducing agents come into contact with painted surfaces or aluminium surfaces during refuelling. u Rinse the affected areas immediately with water.

NOTICE Mixing of special additives and diluting of reduction agents (e.g. with tap water) is not permissible Legally prescribed exhaust gas limit values are not observed.

Ruination of the exhaust gas after-treatment system. u Do not mix the reducing agent with special additives and do not dilute the reducing agent. u Ensure that no dirt mixes with the reducing agent. u Do not fill any fuels into the reducing agent tank. u Do not fill any reducing agent into the diesel fuel tank.

Note u The filler neck diameter of the reducing agent tank is smaller than that of the diesel fuel tank.

NOTICE In the event that diesel fuel is filled into the reducing agent tank or vice versa. u Do not start up the diesel engine. u Consult Liebherr after-sales services.

The reducing agent must remain absolutely pure.

Disposal Dispose of the reducing agent in an environmentally-friendly manner. For correct procedure, see chapter “Disposing of used materials”.

Storage suitability / Temperature-resistance See documentation of the manufacturer.

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If the reducing agent is pumped out of the tank for repair purposes for example, this may not be reused as purity of the fluid can no longer be guaranteed.

Operation, Servicing Operation

Availability Reducing agents can be purchased at petrol filling stations and service stations, or from producing companies and trading companies. Reference points in Europe are listed under www.findadblue.com To purchase reducing agents in the USA, please contact Liebherr Newport News, VA, (757) 245-5251, info.lme@liebherr.com oder www.discoverdef.com.

Utilisation Utilisation of reducing agents for the diesel engine depends on the respective application of the vehicle. Refuelling is not dependent on maintenance. The filling level of the reducing agent tank is indicated via a tank display in the machine cab.

For procedures or information regarding refuelling, see documentation of the machine manufacturer.

Indicator lamps and warning lamps The various conditions of the SCR-system are indicated to the user via illumination of the respective display lamps.

Indicator lamps and warning lamps: Lamp

Designation

Meaning

Remedy

Malfunction of the exhaust gas after-treatment system or filling level of reducing agent tank not OK

Top up reducing agent and/or consult Liebherr after-sales services

MIL-lamp (Malfunction Indicator Lamp)

MIL-lamp (used

by LWE)

DEF-lamp

Tab. 6: SCR indicator lamps and warning lamps

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Warning and malfunction strategies The SCR system is monitored by a diagnosis system. As soon as the diagnosis system detects an error, for example the filling level for the reducing agent tank is not OK, reducing agent quality is poor, malfunctioning of an SCR component or a manipulation of the SCR-system, a warning strategy or a malfunction strategy is activated.

The warning strategies and malfunction strategies differ in relation to the individual legally prescribed requirements (emissions legislations as stipulated by EU Stage IIIB or US EPA/CARB Tier4i) and in relation to respective utilisation of the diesel engine.

The various warming strategies and malfunction strategies are represented in the following tables.

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Operation, Servicing Operation

EU strategies (Stage IIIB) Utilisation

Display

System-Status

Limitation

MIL off

DEF yellow

Stationary applications of truck cranes (uppercarriage)

DEF-Level < 20% or malfunction of the exhaust gas afterNo restriction treatment system 0 h - 50 h

Acoustic signal

MIL yellow

DEF red

DEF-Level < 10% or malfunction of the exhaust gas afterNo restriction treatment system from 50 h

Acoustic signal

MIL off

DEF yellow

Acoustic signal

MIL flashing yellow

DEF flashing yellow

DEF-Level < 10% or malfunction of the exhaust gas afterNo restriction treatment system from 50 h

Acoustic signal

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On-road applications for truck cranes (undercarriage)

DEF-Level < 20% or malfunction of the exhaust gas afterNo restriction treatment system 0 h - 50 h

Operation, Servicing Operation

Utilisation

Display

MIL off

DEF yellow

Off-road applications

System-Status

Limitation

DEF-Level < 20% or malfunction of the exhaust gas afterNo restriction treatment system 0 h - 50 h

Acoustic signal

MIL yellow

DEF red

DEF-Level < 10% or malfunction of the exhaust gas afterNo restriction treatment system from 50 h

Acoustic signal

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Tab. 7: EU strategies (Stage IIIB)

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Operation, Servicing Operation

US-EPA/CARB strategies (Tier4i) Utilisation

Display

MIL off

DEF yellow

System-Status

Limitation

DEF-Level < 20% or malfunction of the exhaust gas after-treatment system 0 min 60 min

No restriction

DEF-Level < 15% or malfunction of the exhaust gas after-treatment system 60 min 180 min

Torque limitation at 80%

DEF-Level < 10% or malfunction of the exhaust gas after-treatment system 180 min 210 min

Torque limitation at 20%

DEF-Level < 5% or malfunction of the exhaust gas aftertreatment system from 210 min

Torque limitation at 20%

Acoustic signal

MIL yellow

DEF yellow

Stationary applications of truck cranes (uppercarriage)

Acoustic signal

MIL yellow

DEF red

MIL red

DEF red

Acoustic signal

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Acoustic signal

Operation, Servicing Operation

Utilisation

Display

MIL off

DEF yellow

System-Status

Limitation

DEF-Level < 20% or malfunction of the exhaust gas after-treatment system 0 min 60 min

No restriction

DEF-Level < 15% or malfunction of the exhaust gas after-treatment system 60 min 180 min

Maximum vehicle speed 45 mph

DEF-Level < 10% or malfunction of the exhaust gas after-treatment system 180 min 210 min

Maximum vehicle speed 5 mph

DEF-Level < 5% or malfunction of the exhaust gas aftertreatment system from 210 min

Maximum vehicle speed 5 mph

Acoustic signal

MIL flashing yellow

DEF yellow

On-road applications for truck cranes (undercarriage)

Acoustic signal

MIL flashing yellow

DEF flashing yellow

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Acoustic signal

MIL yellow

DEF flashing yellow

Acoustic signal

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Operation, Servicing Operation

Utilisation

Display

MIL off

DEF yellow

System-Status

Limitation

DEF-Level < 20% or malfunction of the exhaust gas after-treatment system 0 min 60 min

No restriction

DEF-Level < 15% or malfunction of the exhaust gas after-treatment system 60 min 180 min

Torque limitation at 80%

DEF-Level < 10% or malfunction of the exhaust gas after-treatment system 180 min 210 min

Torque limitation at 20%

DEF-Level < 5% or malfunction of the exhaust gas aftertreatment system from 210 min

Torque limitation at 20%

Acoustic signal

MIL yellow

DEF yellow

Off-road applications

Acoustic signal

MIL yellow

DEF red

Acoustic signal

DEF red

Acoustic signal Tab. 8: US EPA/CARB strategies (Tier4i)

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MIL red

Operation, Servicing Operation

Note u The restrictions are not implemented suddenly, but rather are incorporated gradually.

DANGER Low vehicle speed for on-road applications of truck cranes (undercarriage)!

Traffic obstruction/increased risk of accident u Observe the display indicator.

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u Top up the reducing agent in good time or consult Liebherr after-sales services.

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Operation, Servicing

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Operation

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4 Malfunctions

Troubleshooting can prove difficult for diesel engines. For possible problems of the diesel engine with potential causes and correction measures, see the table Faults Cause - Remedy.

Note

Faults in the diesel engine are indicated via error code on the machine display for diagnosis. An explanation and a remedy are described in the respective machine documentation.

Tab. 9 Fundamental logical steps for diagnosis are included in the following list: – Knowing the diesel engine and all associated systems.

– Scrutinise the problem thoroughly.

– Relate the problem and knowledge of the diesel engine and its systems.

– Diagnose the problem, whereby the simplest assumptions are worked upon.

– Double check before beginning disassembly.

– Establish the causes and perform repair work thoroughly.

– Following repair, allow the diesel engine to run under normal operating conditions and check whether the problem and the cause have been remedied.

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4.1 Faults - Cause - Remedy Malfunction / error

Cause

Remedy

Starter is not turning

Main fuse burned out

Replace the fuse

Battery connections loose or corroded

Clean and tighten loose connections

Battery voltage too low

Charge or replace battery

Starter current circuit broken or contacts corroded

Consult Liebherr after-sales services

Starter faulty

Consult Liebherr after-sales services

Battery voltage too low

Charge or replace battery

Battery connections loose or corroded

Clean and tighten loose connections

Ambient temperature too low

Observe the measures for winter operation

Starter is only turning slowly

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Malfunctions Faults - Cause - Remedy

Malfunction / error

Cause

Remedy

Diesel engine will not start or is cutting out again immediately after starting

Fuel tank empty

Refuel and bleed the fuel system

Fuel filter clogged

Replace fuel filter

Fuel line, pre-cleaner or sieve in fuel Clean and bleed the fuel system tank clogged

Start-up of diesel engine poor

Seal and bleed

Air in the fuel system

Bleed the fuel system

Fuel not cold-resistant

Clean prefilter, replace fuel filter; Use winter fuel

Ambient temperature too low

Observe the measures for winter operation

Heater flange faulty (at colder temperatures)

Check heater flange, replace as necessary

Leakages or insufficient pressure in fuel low-pressure circuit

Inspect for leaks (visual inspection); have an inspection carried out by Liebherr after-sales services

Diesel engine compression too low

Consult Liebherr after-sales services

Heater flange faulty (at colder temperatures)

Check heater flange, replace as necessary

Fault in the electronics

Read out the error memory of the engine control unit, consult Liebherr after-sales services

Supply of voltage interrupted

Consult Liebherr after-sales services

Leakages or insufficient pressure in fuel low-pressure circuit

Inspect for leaks (visual inspection); have inspection carried out by Liebherr after-sales services

Fault in the electronics

Read out error memory of the engine control unit, consult Liebherr after-sales services

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Diesel engine cutting out without warning

Fuel system or filter not properly sealed

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Malfunctions Faults - Cause - Remedy

Malfunction / error

Cause

Remedy

Poor diesel engine output (output deficiency)

Fault in the fuel system (clogged, leaking)

Visual inspection for leaks, replace filter, consult Liebherr after-sales services

Charging pressure too low

Loose brackets, faulty seals and hoses, air filter contaminated, turbocharger has no output

Charge air temperature too high (automatic output reduction via engine control unit)

Charge air cooler contaminated, poor fan output, ambient temperature too high, consult Liebherr aftersales services

Coolant temperature too high (automatic output reduction via engine control unit)

Inspect cooler for contamination, check fan and thermostat, check coolant level, consult Liebherr aftersales services

Fuel temperature too high (automatic output reduction via engine control unit)

Consult Liebherr after-sales services

Application area higher than 1800 m No remedy, diesel engine output above sea level was reduced automatically

Poor diesel engine braking action

Injection nozzles are sticking or are not atomising

Consult Liebherr after-sales services

Diesel engine compression too low

Consult Liebherr after-sales services

Fault in the electronics

Read out error memory of the engine control unit, consult Liebherr after-sales services

Exhaust gas after-treatment system clogged

Consult Liebherr after-sales services

Diesel engine brake flap not functioning

Visual inspection and functional inspection; Consult Liebherr aftersales services

Fault in the electronics

Consult Liebherr after-sales services

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Diesel engine becoming too hot (as Insufficient coolant indicated by the coolant temperature Inside of cooler contaminated or display) calcified, exterior of cooler heavily contaminated

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Top up Clean or decalcify

Thermostat faulty

Check, replace as necessary, consult Liebherr after-sales services

Coolant temperature sensor faulty

Check, replace as necessary, consult Liebherr after-sales services

Insufficient fan speed (hydrostatic fan speed only)

Check fan drive, replace as necessary, consult Liebherr after-sales services

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Malfunctions Faults - Cause - Remedy

Malfunction / error

Cause

Remedy

Indicator lamp for charge current lights up with diesel engine running

Insufficient tension of ribbed V-belt

Check V-belt tension, if necessary replace the tensioning pulleys

Ribbed V-belt torn

Replace ribbed V-belt

Cable connections loose or disconnected

Secure or replace cable

Generator, rectifier or regulator faulty

Consult Liebherr after-sales services

Diesel engine producing black smoke

Exhaust gas after-treatment system faulty

Consult Liebherr after-sales services

Exhaust emissions blue in colour

Oil level in diesel engine too high

Rectify the oil level

Lube oil entering the combustion chamber and becoming burnt

Consult Liebherr after-sales services

Seal on compactor side on the exhaust turbocharger faulty

Consult Liebherr after-sales services

Crankcase ventilation faulty

Check, replace as necessary

Injection begin too late

Consult Liebherr after-sales services

Heater flange faulty (at colder temperatures)

Check heater flange and replace as necessary

Diesel engine knocking

Combustion faults

Consult Liebherr after-sales services

Diesel engine tapping

Valve clearance too great

Adjust valve clearance

Injection nozzles damaged or carbonised

Consult Liebherr after-sales services

Bearing damage

Consult Liebherr after-sales services

Piston rings worn or broken, piston chewed

Consult Liebherr after-sales services

Unusual noises

Lube oil pressure too low

Leakages at the induction and Remedy the leakage, replace seal exhaust lines cause whistling noises as necessary Rubbing of the turbine wheel or compactor wheel on the housing; Foreign bodies in compactor or turbine; Seized bearing of rotating parts

Consult Liebherr after-sales services

Oil level in oil sump too low

Fill in oil up to the prescribed marker

Lube oil too thin (thinning of oil due to diesel fuel)

Drain oil, fill in prescribed oil

Pressure sensor faulty

Check oil pressure and replace damaged oil pressure sensor; Consult Liebherr after-sales services

Final regulating valve not functioning Consult Liebherr after-sales services correctly or dirt in final regulating valve

Lube oil in the cooling system

Bearing clearances too great due to wear or bearing damage

Consult Liebherr after-sales services

Oil cooler or oil cooler plate leaking

Consult Liebherr after-sales services

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Exhaust emissions white in colour

Malfunctions Faults - Cause - Remedy

Malfunction / error

Cause

Remedy

Cooling water in lube oil

O-rings on the cylinder liners leaking Consult Liebherr after-sales services Consult Liebherr after-sales services

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Oil cooler or oil cooler plate leaking

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Malfunctions

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Faults - Cause - Remedy

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5 Maintenance

5.1 Maintenance and inspection chart Abbreviations used in this section: Bh or h = Operating hours Different indicators (solid circle, box, star and blank circle, box, star) divide the maintenance tasks into two groups.

Table with solid circle, box, star means: The maintenance tasks must be performed here by the machine operator or their maintenance personnel under their own responsibility.

Table with blank circle, box, star means:

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The maintenance and inspection tasks must be performed or supervised here by Liebherr specialist personnel or their authorised dealers. The maintenance intervals apply as follows: Upon commissioning and then every 500, 1000, 2000 operating hours (h) and special intervals.

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Maintenance Maintenance and inspection chart Customer:.......................... Machine type:.....................................Serial no.:...................Service hours:.........................Date:.................................

Other intervals

All 3000 h

All 2000 h

All 500 h

All 1000 h

All 50 h

All 8-10 h

On handover

Maintenance / inspection after service hours

Tasks to be performed By maintenance staff n Once-only activity l Repeat interval ª As necessary T Annually before the winter

with authorised specialist staff o Once-only activity m Repeat interval ² As necessary

Diesel engine l l m m m m

Check engine oil level (or in accordance with the oil level sensor display in the cab)

l l m m m m

Visual inspection (leaks, contamination, damages)

m m m m

Check the flap of the diesel engine brake

m m m m

Change diesel engine oil (however, at least once a year): CAUTION! Only E6 diesel engine oil may be used. Other oil qualities and difficulty factors: see Fuel and lubricants

m m m m

Replace the oil filter element (however at least once a year)

m m m m

Replacing the oil separator filter element

m m m m

Check condition of belt drive, replace as necessary / check tension of ribbed V-belt and adjust as necessary

o m m m

Check induction and exhaust systems for sound condition, secure fastening and leaks

m

Grease the flywheel starter ring gear

m m m

Check oil sump, engine mounting and diesel engine brackets for secure fastening T

Check the heater flange

m10000h Replace the heater flange Cylinder head - valves m m m

Check / adjust valve clearance Cooling system

l l m m m m

Check the coolant level

m m m m m

Checking the cooling and heating systems for sound condition and for leaks T

m

Check anticorrosive and antifreeze concentrations in the coolant (however, at least once a year) Replace coolant (or at the latest, every 2 years)

l l m m m m

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

l m m m m

Drain water and sediment in the fuel tank

m m m m

Check lube oil system and fuel system for leaks and for sound condition

m m m

Replace the fuel pre-filter (or with output deficiency)

m m m

Replace the fuel fine filter ²

Bleed the fuel system (injection lines may not be loosened)

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Fuel system

Maintenance Maintenance and inspection chart Customer:.......................... Machine type:.....................................Serial no.:...................Service hours:.........................Date:.................................

Other intervals

All 3000 h

All 2000 h

All 500 h

All 1000 h

All 50 h

All 8-10 h

On handover

Maintenance / inspection after service hours

Tasks to be performed By maintenance staff n Once-only activity l Repeat interval ª As necessary T Annually before the winter

with authorised specialist staff o Once-only activity m Repeat interval ² As necessary

Air filter l l m m m m

Check low-pressure display of the air filter

l m m m m

Cleaning the dust-discharge valve of the air filter ²

Replace dry air filter main element (in accordance with maintenance display / yearly)

²

Replace dry air filter safety element (with every third replacement of the main element / yearly) Electrical system

o m m m

Checking the batteries and cable connections

m m m m

Check control unit mounting for sound condition

o m m m

Ensure sound condition of sensors, actuators, cable fittings and plugs.

SCR-System Replace foam element and filter element of the SCR urea pump (at least every 2 years)

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Maintenance Filling amounts

5.2 Filling amounts 5.2.1 Table for filling amounts Designation Recommended lubricant

Amount

Engine oil

Liebherr engine oil 10W-40 low ash

25 l (1.5 l per filter) D934 A7

Liebherr Antifreeze Mix

15 l

D934 A7

Liebherr Antifreeze Concentrate

20 l

D936 A7 / D946 A7

Coolant

Reducing agent

Reducing agent as stipulated by DIN 70070 / ISO 22241

Engine type

44 l (1.5 l per filter) D936 A7 / D946 A7

See documentation of machine manufacturer

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Tab. 10: Table for filling amounts

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Maintenance Fuels and lubricants

5.3 Fuels and lubricants 5.3.1 Handling fuels and lubricants Conscientious adherence of the guidelines for handling fuel and lubricants increases reliability and life-expectancy of the machine.

It is particularly important that the specified change intervals and qualities of lubricant are respected.

Diverse specifications regarding the prescribed intervals can be obtained in the chapter “Maintenance” under “Maintenance and inspection chart.”

Miscellaneous details for carrying out: lubrication, checking levels and changing fuel can be obtained in the chapter “Maintenance” under “ Maintenance Tasks.”

Observe the environmental guidelines and regulations regarding the handling of fuels and lubricants.

5.3.2 Environmental-protection guidelines u Always observe all environmental-protection guidelines. u Observe the guidelines of the respective countries. u Ensure that correct disposal of any fluids has been arranged before commencing draining.

5.3.3 Disposing of used materials This concerns used materials and hazardous waste such as: – Oils, lubricants, refrigerants for air conditioning systems etc.

– Coolant – Fuels – Filters, oil filter cartridges, etc.

Procedure Note Risk of harm to the environment and to personal health.

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u Observe the guidelines of the respective country for environmental protection when disposing of used materials. u All used materials are to be collected and disposed of in separate containers. u Dispose of all used materials in an environmentally-friendly manner at official disposal stations.

5.3.4 Diesel fuels Specification The diesel fuels must comply with the minimum requirements of the fuel specifications stipulated as follows.

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Maintenance Fuels and lubricants

Permissible specifications: – DIN EN 590 – ASTM D 975 - 1D S15 and 2D S15

Sulphur content in the diesel fuel Diesel fuels with a sulphur content of above or more than 15 mg/kg (0.0015 %) are not permissible.

Diesel fuel lubricity The diesel fuel lubricity must not exceed a maximum 460 µm (lubricity corrected "wear scar diameter" [1.4] at 60°C) as prescribed by HFRR (60) Test.

A written confirmation from the fuel supplier must be on-hand.

Any additions should be undertaken by the supplier as he is responsible for the quality of the fuel. The addition of secondary-lubricity-additives by the customer is not recommended.

Note u Obtain a written confirmation from the supplier.

Ease of ignition A cetane number of at least 45 is required for fuels in accordance with ASTM D 975. A cetane number above 50 is preferable, especially with temperatures below 0°C (32°F).

Diesel fuel at low temperatures (winter operation) Paraffin crystals in the diesel fuel become separated as ambient temperatures drop, increasing flow resistance in the fuel filter to such an extent that a sufficient supply of fuel to the diesel engine can no longer be guaranteed.

WARNING A mixture of petroleum or regular petrol is not permissible, both as a safety precaution and for technical reasons.

If the machine is being operated in arctic climates: u Use special diesel fuels which feature sufficient flow properties.

5.3.5 Lube-oils for the diesel engine Lube oil quality Nowadays, only high-alloy lube oils are used for modern diesel engines.

They consist of base oils which feature combined admixtures (additives).

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

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If the ambient temperature drops below -20°C: u Use a starting aid device (e.g. fuel filter heating).

Maintenance Fuels and lubricants

Designation

Specification

ACEA — classification (Association des Constructeurs Européens de l'Automobile)

E6, E9 E9, Caution: Observe the reduced oil change intervals

API — classification (American Petroleum Institute)

CJ-4 Caution: Observe the reduced oil change intervals.

Tab. 11: Lube oil specifications

Lube-oil viscosity Selection of the lube oil viscosity in accordance with the SAE-classification (Society of Automotive Engineers).

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

Selection of the SAE-class gives no indication of the quality of a lube-oil.

Too high a viscosity can lead to starting difficulties, and too low a viscosity could jeopardise the lubricating efficiency.

The temperature ranges specified in the following diagram are guidelines and can be briefly exceeded or fallen short of.

Fig. 78: Temperature-related selection of SAE-class The following diesel engine oil is recommended for ambient temperatures of -20°C (-4°F) to 45°C (113°F) :

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Liebherr engine oil 10W-40 low ash, Specification ACEA E6 The following diesel engine oil is recommended for ambient temperatures of -30°C (-22°F) to 30°C (86°F) : Liebherr engine oil 5W-30 low ash, Specification ACEA E6

Lube-oil change intervals Change intervals: See the section “Maintenance and inspection chart” Oil-change respective of climatic zone, sulphur content in the fuel and oil quality in accordance with the following table

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Maintenance Fuels and lubricants

If the prescribed operating hours (h) have not expired within one year, the diesel engine oil and filter must be replaced at least once a year.

Different difficulty factors (tougher operating conditions) alter the maintenance interval.

Difficulty factors include: – Repeated cold-starts – Application temperature Should difficulty factors or tougher operating conditions arise, oil-change and filter replacement must be carried out in accordance with specifications in the following table.

Difficulty factor

Oil quality CJ-4 E9

E6

Operating conditions

Sulphur content in the fuel

Interval (h = operating hours)

Climate normal down to -10°C

up to 0.0015 %

250 h

500 h

Climate below -10°C (constant temperature)

up to 0.0015 %

125 h

250 h

Tab. 12: Oil change intervals in correspondence with difficulty factors

5.3.6 Coolant for diesel engine General recommendations Coolant is a mixture of water and additives for anticorrosive and anticorrosive/antifreeze.

Coolant: – Can be mixed with the products specified as follows.

– Is available ready mixed.

The cooling system will only function reliably when pressurised. Keep the cooling system clean and free of leaks. The cooler sealing valve and working valve must be functioning correctly. Ensure that the required coolant level is maintained.

Coolant will cause cavitation or corrosion damage in the cooling system if it does not contain sufficient antifreeze/anticorrosive or if it has not been correctly prepared. Heat insulating deposits on heat-conducting components will lead to overheating and failure of the diesel engine.

Emulsifiable anticorrosive oils are prohibited.

Water (fresh water) Colourless, clear, drinkable tap water which is free of mechanical contamination, and featuring the following restricted analysis values, is suitable to use as fresh water

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Liebherr-approved anticorrosive/antifreeze: – Guarantee sufficient antifreeze, anticorrosive, and cavitation protection.

– Do not grab hold of seals and hoses.

– Do not froth up.

Maintenance Fuels and lubricants

Sea water, brackish water, salt water and industrial waste water is not suitable.

Designation

Value

Sum of alkaline earths (water hardness)

0.6 mmol/dm3 to 3.6 mmol/dm3 (3 to 20 °d)

Ph value at 20°C

6.5 to 8.5

Chloride ion content

Maximum 80 mg/dm3

Sulphate ion content

Maximum 100 mg/dm3

Tab. 13: Fresh water quality Apply for water analyses by the communal authorities responsible.

Coolant — mix ratio The coolant must contain at least 50 % anticorrosive protection all year round.

Ambient temperature up to

Mix ratio Water %

Anticorrosive / antifreeze %

-37°C (-34.6°F)

50

50

-50°C (-58°F)

40

60

Tab. 14: Temperature-dependent mix ratio of water and anticorrosive/antifreeze NOTICE Percentage of anticorrosive/antifreeze in the coolant too high!

Diesel engine is overheating and could sustain damage. u Do not use more than 60% of anticorrosive/antifreeze!

Permitted anticorrosive / antifreeze Product description

Manufacturer

Liebherr Antifreeze Concentrate

Liebherr

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Tab. 15: Permitted anticorrosive / antifreeze Note If there is no Liebherr coolant available locally: u Use a coolant which complies with the "Coolant specification for Liebherr diesel engines 10652041" (consultation with Liebherr after-sales services).

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Maintenance Fuels and lubricants

Note Mixing of different anticorrosive/antifreezes can impair the properties of the coolant. u Do not combine different products! u Under no circumstances may silicate-based and non-silicate coolants be mixed, as this could cause damage within the cooling system.

Permissible ready-mixed anticorrosive/antifreezes Product description

Manufacturer

Liebherr Antifreeze Mix

Liebherr

Tab. 16: Permissible ready-mixed coolants Premix = ready-mix (50 % water and 50 % anticorrosive / antifreeze) Note If there is no Liebherr coolant available locally: u Use a coolant which complies with the "Coolant specification for Liebherr diesel engines 10652041" (consultation with Liebherr after-sales services).

Note Mixing of different anticorrosive/antifreezes can impair the properties of the coolant. u Do not combine different products! u Under no circumstances may silicate-based and non-silicate coolants be mixed, as this could cause damage within the cooling system.

Permitted anticorrosive / antifreeze (inhibitors) without antifreeze In exceptional cases and at ambient temperatures constantly above freezing point, e.g. in tropical regions where there is apparently no approved anticorrosive/ antifreeze available, the water must be mixed with the following anticorrosives to act as a coolant: – Product DCA 4 Diesel Coolant Additives – Product Caltex XLI / Delo XLI / Texaco XLI / Havoline XLI Check the concentration during the course of carrying out the maintenance tasks and rectify as necessary.

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In this case, change the coolant once yearly.

Maintenance Fuels and lubricants

Note Mixing of different anticorrosive / antifreezes can impair the properties of the coolant. u Do not combine different products! u Under no circumstances may silicate-based and non-silicate coolants be mixed, as this could cause damage within the cooling system.

When changing from antifreeze/anticorrosive to anticorrosive and vice versa: u Drain the coolant.

Product description

Manufacturer

DCA 4 Diesel Coolant Additives

Fleetguard / Cummins Filtration

Caltex XLI / Delo XLI

Caltex (Asia)

Texaco XLI / Havoline XLI

Chevron (North and South America)

Havoline XLI

Arteco (Asia and Europe)

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Tab. 17: Permitted anticorrosive / antifreeze (inhibitors) without antifreeze

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Maintenance Special tools for maintenance tasks

5.4 Special tools for maintenance tasks

Fig. 79: Turning gear - Mounting the flywheel housing special tool no. 30 The turning gear special tool no. 30 is optional and can be mounted on any flywheel housing.

No.

ID no.

Designation

See section

30

0524045

Turning gear

Check / adjust valve clearance

Fig. 80: Turning gear - Mounting the belt pulley crankshaft special tool no. 30a The turning gear special tool no. 30a is only included in the delivery scope of the diesel engine and mounted in special cases.

No.

ID no.

Designation

See section

30a

10116805

Turning gear

Check / adjust valve clearance

Tab. 19

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Tab. 18

Maintenance Special tools for maintenance tasks

Fig. 81: Turning gear - Mounting the power takeoff air compressor special tool no.

30b The turning gear special tool no. 30b is optional for air compressor with integrated power take-off.

No.

ID no.

Designation

See section

30b

10128497

Turning gear

Check / adjust valve clearance

Tab. 20

Fig. 82: Turning gear - Mounting the belt pulley crankshaft special tool no. 30c

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Can only be used if the vibration damper is connected with hexagon socket head screws.

No.

ID no.

Designation

See section

30c

10118801

Turning gear

Check / adjust valve clearance

Tab. 21

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Maintenance Special tools for maintenance tasks

Fig. 83: Turning gear - Mounting the power take-off NA4 special tool no. 30d The turning gear special tool no. 30d is optional and is not included in the delivery scope of the diesel engine.

No.

ID no.

Designation

See section

30d

10134822

Turning gear

Check / adjust valve clearance

Tab. 22

The turning gear special tool no. 30e can only be mounted if the idler is included in the delivery scope of the diesel engine (not featured as standard).

No.

ID no.

Designation

See section

30e

10138480

Turning gear

Check / adjust valve clearance

Tab. 23

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Fig. 84: Turning gear - Mounting the power take-off NA2 special tool no. 30e

Maintenance Preparatory maintenance tasks

5.5 Preparatory maintenance tasks Before carrying out diverse maintenance tasks, the diesel engine must be manoeuvred into the maintenance position, unless expressly otherwise specified in the description.

Diverse maintenance tasks include for example: – Checking of the oil level or oil change – Replacing the filter, as well as adjustment or repair tasks.

Safety precautions for maintenance It is imperative that the safety guidelines are observed when carrying out maintenance tasks! See the chapter “Safety guidelines”.

Maintenance points

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The diesel engine is in the maintenance position when: – The diesel engine is positioned horizontally.

– The diesel engine has been shut down.

– The diesel engine has cooled.

– The battery main switch (if featured) is switched off and the key for the battery main switch has been removed.

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Maintenance Maintenance tasks (daily), every 10 operating hours

5.6 Maintenance tasks (daily), every 10 operating hours It must be ensured that: q The diesel engine is in the maintenance position.

5.6.1 Check the engine oil level Arrangement of the oil dipstick and the oil filler nozzle varies depending on the respective diesel engine, e.g. oil dipstick on the left-hand or right-hand side of the engine, oil filler nozzle is located on the oil sump, flywheel housing or on the cylinder head cover.

Fig. 85: Example oil dipstick - oil filler nozzle u Remove the oil dipstick 2, wipe with a clean rag and insert again as far as the stop. u Pull out the oil dipstick once again and determine the oil level. The oil level must be between “min.” and “max”.

u See documentation of the machine manufacturer.

If the oil level is too low: u Remove the oil filler cap. u Fill in oil via the filler neck 1. u Do not fill oil into the diesel engine above the “max.” marking. u Clean the filler cap, fit onto the filler neck and tighten.

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Note Check the engine oil level in accordance with the oil level sensor display.

Maintenance Maintenance tasks (daily), every 10 operating hours

5.6.2 Visual inspection (leaks, contamination, damages) u Check the diesel engine for leaks via visual inspection. u Check lines and hoses for leaks via visual inspection. u Ensure sound condition without indication of damage, correct arrangement without the occurrence of wear and correct fastening of all lines and hoses.

5.6.3 Check the coolant level DANGER Hot cooler components and hot refrigerants!

Burns. u Only carry out maintenance and inspection tasks on the cooling system after the diesel engine has cooled. u Wear protective equipment.

Procedure for checking the coolant level, see documentation of the machine manufacturer.

5.6.4 Checking / draining the water separator of the fuel prefilter It must be ensured that: q A collecting vessel featuring the necessary volumetric capacity is on-hand.

The fuel prefilter with water separator and fuel manual delivery pump is mounted away from the diesel engine, the exact position varying in accordance with configuration of the machine.

WARNING Naked flames!

Fire and explosion. u When carrying out maintenance and inspection tasks on the fuel system, do not handle naked flames.

LMB/10140787/00/01.01.2012/en

u Only carry out maintenance and inspection tasks if the diesel engine has been shut down.

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Maintenance Maintenance tasks (daily), every 10 operating hours

Draining the fuel pre-filter

Fig. 86: Draining the fuel prefilter u Check the water separator of the fuel pre-filter.

Troubleshooting Water has been determined in the water separator of the fuel prefilter? u Do not start the diesel engine. u Position collecting vessel beneath the water separator. u Loosen the bleed screw 1 and turn around two turns (in an anticlockwise direction). u To open the shut-off tap: Pull out the blue locking handle 2 and at the same time turn around 90° in an anticlockwise direction.

LMB/10140787/00/01.01.2012/en

If water drains out: u Close the shut-off tap. Turn the blue locking handle 2 around 90° in a clockwise direction (the locking handle engages again automatically).

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Maintenance Maintenance tasks (daily), every 10 operating hours

Bleeding the fuel prefilter

Fig. 87: Bleeding the fuel prefilter u Turn the marking 2a “PU” in the direction of the arrow (in an anticlockwise direction). u Continue to actuate the manual delivery pump 2b until bubble-free fuel flows out at the bleed screw 1. u Tighten the bleed screw with a tightening torque of 6 Nm. To allow start-up of the diesel engine: u Turn the “arrow” marking 2c in the direction indicated by the arrow (clockwise).

5.6.5 Check low-pressure display of the air filter

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Procedure for checking the underpressure display for the air filter, see documentation of the machine manufacturer.

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Maintenance Maintenance tasks (weekly) every 50 operating hours

5.7 Maintenance tasks (weekly) every 50 operating hours It must be ensured that: q The diesel engine is in the maintenance position.

5.7.1 Drain water and sediment in the fuel tank WARNING Naked flames!

Fire and explosion. u When carrying out maintenance and inspection tasks on the fuel system, do not handle naked flames. u Only carry out maintenance and inspection tasks if the diesel engine has been shut down.

Procedure for draining water and sediment in the fuel tank, see documentation of the machine manufacturer.

When refuelling, maintain the level of fuel as high as possible in the tank, in order that condensation is reduced to a minimum.

5.7.2 Cleaning the dust-discharge valve of the air filter

LMB/10140787/00/01.01.2012/en

Procedure for cleaning the dust-discharge valve of the air filter, see documentation of the machine manufacturer.

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Maintenance Maintenance tasks, every 500 operating hours

5.8 Maintenance tasks, every 500 operating hours It must be ensured that: q The diesel engine is in the maintenance position.

5.8.1 Check the flap of the diesel engine brake The diesel engine brake is mounted on the exhaust stack on the left-hand side of the diesel engine.

Fig. 88: Diesel engine brake flap WARNING Brake flap sticking!

Damage to the diesel engine u Ensure that the brake flap returns freely into its original position after it has been actuated. u Inspect and grease the articulations of the actuating cylinder. u Actuate the brake flap.

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5.8.2 Changing diesel engine oil and replacing the oil filter The oil drain valve is mounted on the diesel engine, either at the bottom or on the side of the oil sump.

It must be ensured that: q The diesel engine is positioned horizontally. q The diesel engine has been shut down. q The diesel engine is warm. q Two original LIEBHERR oil filter cartridges are on-hand. q A collecting vessel featuring the necessary volumetric capacity is on-hand. q A suitable drainage hose from the machine manufacturer is on-hand. q Diesel engine oil is on-hand. For the amount of diesel engine oil, see the chapter “Table for filling amounts”. For lube-oil specification, see the chapter “Fuel and lubricants”.

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Maintenance Maintenance tasks, every 500 operating hours

Draining the diesel engine oil

Fig. 89: Drain valve with drainage hose CAUTION Hot engine oil!

Burns. u Avoid skin contact with the engine oil. u Wear protective industrial gloves when changing the oil. u Unscrew the sealing cap on the oil drain valve on the oil sump. u Screw the oil drainage hose onto the oil drain valve. u Allow the oil to drain into the container provided. u Dispose of the oil (for correct procedure, see the chapter “Disposing of used materials”). u Unscrew the oil drainage hose and screw the sealing cap onto the oil drain valve.

Note

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u For diesel engines with integrated power take-offs on the bottom of the flywheel housing, the drain plugs must be opened when changing the diesel engine oil.

Fig. 90: Flywheel housing with power take-offs

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Maintenance Maintenance tasks, every 500 operating hours

u Unscrew both screw plugs u Allow the oil to drain into the container provided. u Screw in the screw plugs.

Note u For diesel engines featuring oil sump (small sump), the drain plug must be open when replacing the diesel engine oil.

Fig. 91: Oil sump (small sump) u Unscrew the screw plug. u Allow the oil (approx. 3 L) to drain into the prepared container. u Screw in the screw plug.

Replacing the oil filter The oil filters are mounted upright on the aggregate carrier of the diesel engine.

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It must be ensured that: q A strap wrench or a hexagonal wrench SW 30, a suitable container, as well as original LIEBHERR oil filter cartridges (2 x) are on-hand

Fig. 92: Oil filter u Position a suitable container under the diesel engine.

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Maintenance Maintenance tasks, every 500 operating hours

Note u Protect the ribbed V-belt against escaping oil when replacing the oil filter cartridges! u After replacing the oil filter, remove all traces of oil on the diesel engine, as well as behind the vibration damper in order that this will not be later diagnosed as leaks in the rotary shaft seal. u Loosen the oil filter cartridges 1 with a strap wrench or hexagonal wrench SW 30 and unscrew the filter. u Clean the sealing faces of the filter bracket. w Old filter seal and its residues have been removed. u Apply a thin coat of diesel engine oil to the rubber sealing ring on the new oil filter cartridge. u Screw on the new oil filter cartridge until the sealing ring is resting on the filter bracket w The sealing ring is resting on the filter bracket: u Tighten the oil filter cartridge; 3/4 to 1 full turn / 20 Nm- 5 Nm.

Filling diesel engine oil

Fig. 93: Diesel engine-oil filler nozzle

u Do not fill oil into the diesel engine above the “max.” marking. u Clean the filler cap, fit onto the filler neck and tighten. u Start the diesel engine and check the oil pressure. u Switch off the diesel engine and after 2 - 3 minutes check the oil level on the dipstick.

Troubleshooting The oil level is not within min. and max.? u Rectify the oil level.

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u Fill in oil via the filler neck 1.

Maintenance Maintenance tasks, every 500 operating hours

5.8.3 Replacing the oil separator filter element It must be ensured that: q An oil separator filter element is on-hand.

The oil separator is mounted on the right-hand side of the diesel engine on the same side of the flywheel.

Fig. 94: Oil separator u Clean the oil separator and the surrounding area thoroughly. u Unscrew and remove the oil separator sealing cap, if necessary use a screwdriver. u Pull out the oil separator filter element and dispose of in an environmentallyfriendly manner (for correct procedure, see the chapter “Disposing of used materials”). u Insert new oil separator filter element and push in up to the stop.

Note

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u Observe the directions of the arrow for sealing cap and housing!

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Maintenance Maintenance tasks, every 500 operating hours

Fig. 95: Oil separator - directions of arrow u Mount the oil separator sealing cap and tighten by hand to the stop.

5.8.4 Checking and replacing the ribbed V-belt Damages to the ribbed V-belt include: – Rib fractures.

– Rubber nodules at the base of the ribs.

– Accumulation of dirt and/or stones.

– Ribs becoming loose at the base of the ribs.

– Transversal fractures on the belt exterior.

– Transversal fractures in several ribs.

Mounting of the belt is self-tightening and is maintenance-free.

The belt drive is located at the front on the diesel engine.

Run of the ribbed V-belt may vary depending on the circumference of the diesel engine, e.g for generator drive and generator drive with air-conditioning compressor.

WARNING Rotating components! u Switch off diesel engine. u Observe the after-run time: Ensure before opening the covers that all parts have stopped moving. u Dismantle the ribbed V-belt guard (optional) u Check the ribbed V-belt for damage. u Ensure sound condition and correct clearance of pulley and tensioning pulley.

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Checking the ribbed V-belt

Maintenance Maintenance tasks, every 500 operating hours

Troubleshooting Damage has been determined? u Replace damaged parts.

Replacing ribbed V-belts It must be ensured that: q A new ribbed V-belt is on-hand. q A ratchet DIN 3122 D 12.5 (1/2') is on-hand.

WARNING Rotating components! u Switch off diesel engine. u Observe the after-run time: Ensure before opening the covers that all parts have stopped moving.

Fig. 96: Ribbed V-belt generator drive with air-conditioning compressor u Pivot back the tensioning device against the spring force in an anticlockwise direction as far as it will go. u Remove the ribbed V-belt. u Check tensioning roller and belt pulley for sound condition (e.g. worn bearing of tensioning roller, as well as wear of the belt pulley profile).

Troubleshooting Damage has been determined?

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u Replace damaged parts.

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Maintenance Maintenance tasks, every 500 operating hours

Fig. 97: Ribbed V-belt run variants 1

Belt pulley Crankshaft

4

2 3

Belt pulley Generator Tensioning device

5

Belt pulley Air-conditioning compressor Deflection pulley

u Mount new ribbed V-belt with pivoted back tensioning device onto the belt pulley of the crankshaft, air-conditioning compressor, generator and deflection pulley. u Mount the ribbed V-belt guard (optional)

5.8.5 Checking induction and exhaust gas system for sound condition and for leaks Note The control interval is 1000 h. u These maintenance tasks are only to be carried out once after 500 operating hours. u Check the suction lines between air filter and diesel engine for sound condition, leaks and secure fastening. u Check exhaust lines for sound condition, leaks and secure fastening.

DANGER Hot cooler components and hot refrigerants!

Burns. u Only carry out maintenance and inspection tasks on the cooling system after the diesel engine has cooled. u Wear protective equipment. u Check cooler, coolant pump and heat exchanger for the heating system for leaks. u Check all lines and hoses of the cooling and heating system for leaks, ensure that they are correctly arranged without abrading one another and that they are free of damage.

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5.8.6 Check the cooling and heating systems for sound condition and for leaks

Maintenance Maintenance tasks, every 500 operating hours

u Check cooler for external contamination. The fins should not become clogged with dirt.

Troubleshooting If leaks are determined in the cooling system: u Do not start the diesel engine. u Remedy the cause.

5.8.7 Checking lubrication system and fuel system for leaks and for sound condition u Check oil sump, oil filter, fuel delivery pump and fuel filter for leaks. u Check all lines and hoses of the oil and fuel systems, ensure that they are correctly arranged without abrading one another, are free of damage and are securely fastened.

Troubleshooting Leaks have been determined in the oil and fuel system? u Do not start the diesel engine. u Determine and remedy the cause and replace any damaged parts.

5.8.8 Checking the batteries and cable connections Note The control interval is 1000 h. u These maintenance tasks are only to be carried out once after 500 operating hours.

Procedure for checking the batteries and cable connections, see documentation of the machine manufacturer.

5.8.9 Checking the control unit mounting for sound condition

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u Check the control unit mounting for damage and secure fastening.

Troubleshooting Damaged bearings have been determined? u Do not start the diesel engine. u Replace all bearings.

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Maintenance Maintenance tasks, every 500 operating hours

5.8.10 Checking sensors, actuators, cable fittings and plugs for sound condition Note The control interval is 1000 h. u These maintenance tasks are only to be carried out once after 500 operating hours. u Ensure secure seating and sound condition of all sensors, actuators, cable connections and plugs. u Ensure sound condition without indication of damage, correct arrangement without the occurrence of wear and correct fastening of all cables and cable harness.

Troubleshooting Damage to cable connections, cable harness or sensors has been determined? u Do not start the diesel engine.

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u Replace faulty parts.

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Maintenance Maintenance tasks every 1000 operating hours

5.9 Maintenance tasks every 1000 operating hours It must be ensured that: q The diesel engine is in the maintenance position.

5.9.1 Checking the oil sump, engine mount and diesel engine brackets for secure seating u Ensure secure seating of the oil sump and retighten the screws as necessary.

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u Ensure sound condition and secure fastening of diesel engine brackets and engine mount, if necessary retighten the screws.

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Maintenance Maintenance tasks every 1000 operating hours

5.9.2 Checking and adjusting valve clearance It must be ensured that: q A special tool turning gear is on-hand. See the chapter “Special tools for maintenance tasks”.

Note u Cylinder 1 is situated on the same side as the flywheel. u Rotational direction to the left looking at the flywheel u The exhaust valve of the respective cylinder is situated on the same side as the flywheel.

Fig. 98: Valves of the cylinder A = Exhaust valve E = Intake valve Valves of the cylinder D934 A7 Overlap

4

2

1

3

adjust

1

3

4

2

Tab. 24: Valves of the cylinder D934 A7

Overlap

6

2

4

1

5

3

adjust

1

5

3

6

2

4

Tab. 25: Valves of the cylinder D936 A7 / D946 A7

Checking and adjusting valve clearance standard u Remove the cylinder head covers. u Fit the turning gear.

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Valves of the cylinder D936 A7 / D946 A7

Maintenance Maintenance tasks every 1000 operating hours

u Continue to turn the crankshaft with turning gear in the direction of rotation until the valves of the cylinder being adjusted overlap. For details, see the table “Valve of the cylinder D934 A7” or “Valves of the cylinder D936 A7 / D946 A7”.

Fig. 99: Checking / adjusting intake valve clearance

Fig. 100: Checking / adjusting exhaust valve clearance u Insert feeler gauge between valve fitting and rocker arm and check valve clearance.

Troubleshooting The clearance does not correlate with the adjustment values (see the chapter “Technical data, valve clearance”)?

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u Loosen the lock nut on the adjusting screw of the respective rocker arm and adjust the setting. u Tighten the lock nut with 45 Nm. u Check the setting again. u Following checking and/or adjustment of all valves, fit the cylinder head covers with inspected and approved damage-free seals. u Dismantle the turning gear.

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Maintenance Maintenance tasks every 1000 operating hours

Checking valve clearance and adjusting with engine auxiliary brake system (ZBS) Checking and adjusting intake valve clearance u Remove the cylinder head covers. u Fit the turning gear. u Continue to turn the crankshaft with turning gear in the direction of rotation until the valves of the cylinder being adjusted overlap. For details, see the table “Valve of the cylinder D934 A7” or “Valves of the cylinder D936 A7 / D946 A7”.

Fig. 101: Checking / adjusting intake valve clearance u Insert feeler gauge between valve fitting and rocker arm and check valve clearance.

Troubleshooting The clearance does not correlate with the adjustment values (see the chapter “Technical data, valve clearance”)? u Loosen the lock nut on the adjusting screw of the respective rocker arm and adjust the setting. u Tighten the lock nut with 45 Nm. u Check the setting again. u Following checking and/or adjustment of all valves, fit the cylinder head covers with inspected and approved damage-free seals.

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u Dismantle the turning gear.

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Maintenance Maintenance tasks every 1000 operating hours

Checking exhaust valve clearance

Fig. 102: Valve clearance exhaust valve fitting/rocker arm u Insert the feeler gauge between exhaust valve fitting and adjusting screw-rocker arm and check valve clearance.

Troubleshooting The clearance does not correlate with the adjustment values (see the chapter “Technical data, valve clearance”)? u Setting the valve clearance

Fig. 103: Valve clearance exhaust valve fitting/retainer

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u Insert the feeler gauge between exhaust valve fitting and adjusting screwretainer and check valve clearance.

Troubleshooting The clearance does not correlate with the adjustment values (see the chapter “Technical data, valve clearance”)? u Setting the valve clearance

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Maintenance Maintenance tasks every 1000 operating hours

Adjusting the exhaust valve clearance

Fig. 104: Valve clearance exhaust valve fitting/rocker arm u Continue to turn back adjusting screw 2 until the contact face of the adjusting screw disappears inside the retainer. u Continue to turn back adjusting screw 1 until it is possible to insert the feeler gauge which corresponds with the respective adjustment value. u Screw in adjusting screw 1 until the piston in the exhaust valve fitting reaches the stop and clamps the feeler gauge. u Continue to loosen adjusting screw 1 until the feeler gauge can be withdrawn against moderate resistance (suction). u Tighten the lock nut of adjusting screw 1 with 45 Nm .

u Continue to screw in adjusting screw 2 with the feeler gauge corresponding with the respective adjustment value inserted, until the piston of the valve fitting reaches the stop and the feeler gauge becomes clamped. u Continue to loosen adjusting screw 2 until the feeler gauge can be withdrawn against moderate resistance (suction). u Tighten the lock nut of adjusting screw 2 with 45 Nm. w The push rod must indicate clearance. u Check the settings once again. u Following checking and/or adjustment of all valves, fit the cylinder head covers with inspected and approved damage-free seals. u Dismantle the turning gear.

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Fig. 105: Valve clearance exhaust valve fitting/retainer

Maintenance Maintenance tasks every 1000 operating hours

5.9.3 Replacing the fuel prefilter element It must be ensured that: q A collecting vessel featuring the necessary volumetric capacity is on-hand. q A fuel prefilter element is on-hand.

The fuel prefilter with water separator and fuel manual delivery pump is mounted away from the diesel engine, the exact position varying in accordance with configuration of the machine.

WARNING Naked flames!

Fire and explosion. u When carrying out maintenance and inspection tasks on the fuel system, do not handle naked flames. u Only carry out maintenance and inspection tasks if the diesel engine has been shut down.

If a fuel shut-off valve is featured: u Close the fuel shut-off valve.

Fig. 106: Fuel prefilter u Position the collecting vessel beneath the fuel pre-filter.

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u Open the shut-off tap. For correct procedure, see the chapter “Checking / draining the water separator on the fuel prefilter”. u Unscrew the screws 2 and remove the cover 3 with seal 4. u Remove the fuel prefilter element 5 together with the spring cassette 7. u Dispose of the fuel prefilter element 5.

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Maintenance Maintenance tasks every 1000 operating hours

WARNING Dirt!

Ruination of the Common Rail System. u Ensure that no dirt penetrates the clean side of the filter. u Leave residual diesel fuel in the filter housing. u Do not reuse fuel prefilters once used. u Refer to the special information regarding working on the Common Rail System, see the chapter “Special notes on safety”. u Install the new fuel prefilter element 5. u Inspect the seal 4 and replace as necessary, then reassemble in reverse order. u Open the fuel shut-off valve and bleed the fuel system. For correct procedure, see the chapter “Bleeding the fuel system”.

5.9.4 Replacing the fuel fine-filter It must be ensured that: q A collecting vessel featuring the necessary volumetric capacity is on-hand. q Two LIEBHERR fuel fine filters are on-hand. q A suitable drainage hose from the machine manufacturer is on-hand.

The fuel fine filters are situated on the right-hand side of the diesel engine.

WARNING Naked flames!

Fire and explosion. u When carrying out maintenance and inspection tasks on the fuel system, do not handle naked flames. u Only carry out maintenance and inspection tasks if the diesel engine has been shut down.

If a fuel shut-off valve is featured: u Close the fuel shut-off valve. u Position the collecting vessel beneath the fuel fine filter.

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u Clean the fuel fine filter and the surrounding area thoroughly.

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Maintenance Maintenance tasks every 1000 operating hours

Fig. 107: Replacing the fuel fine filter u Loosen the filter cartridge 1 with a strap wrench or similar tool and unscrew. u Dispose of the old fuel fine filter. u Check cleanliness of filter base and ensure that the thread adapter is sitting securely in the filter base.

If the filter base is dirty: u Clean the filter base. u Lubricate the sealing ring 2 of the new filter with clean fuel or oil.

WARNING Dirt!

Ruination of the Common Rail System. u Ensure that no dirt penetrates the clean side of the filter. u Do not use fuel fine filters again once used. u Refer to the special information regarding working on the Common Rail System, see the chapter “Special notes on safety”. u Fill the new filter with clean fuel. u Continue to screw on the filter until the sealing ring is resting on the filter head. u Tighten the filter manually around 3/4 of a turn.

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u Open the fuel shut-off valve and bleed the fuel system. For correct procedure, see the chapter “Bleeding the fuel system”.

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Maintenance Maintenance tasks every 2000 operating hours

5.10 Maintenance tasks every 2000 operating hours It must be ensured that: q The diesel engine is in the maintenance position.

5.10.1 Checking anticorrosive / antifreeze concentration in the coolant Coolant must contain at least 50 %, but more than 60% of anticorrosive / antifreeze all year round. A coolant with 50 Vol.% anticorrosive/antifreeze corresponds with a freeze protection up to approx. -37°C.

Checking the anticorrosive/antifreeze concentration DANGER Hot refrigerant!

Burns. u Before opening the filler neck, allow the engine to cool. u Open the sealing cap on the filler neck carefully. u Take a sample of the coolant and analyse with an appropriate test procedure.

If the analysis yields a low frost protection: u Adjust the mix ratio of the anticorrosive/antifreeze in the coolant.

Adjusting the correct anticorrosive/antifreeze concentration NOTICE Percentage of anticorrosive/antifreeze in the coolant too high!

Diesel engine is overheating and could sustain damage. u Do not use more than 60% of anticorrosive/antifreeze!

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If the anticorrosive/antifreeze concentration is too low: u Drain the coolant and refill in accordance with the following anticorrosive/antifreeze calculation formula.

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Maintenance Maintenance tasks every 2000 operating hours

Fig. 108: Calculation formula for filling amount of anticorrosive / antifreeze, example 29 Vol.% (corresponds with –15°C) u For the correct filling amount of coolant, see documentation of the machine manufacturer.

Utilisation of anticorrosive without antifreeze Utilisation of DCA 4 u Remove a sample of coolant and analyse with test kit CC 2602 M from Fleetguard.

If the analysis does not yield a DCA 4 concentration of between 0.6–1.06 units per litre: u Adjust the mix ratio, see specifications of the manufacturer.

Utilisation of water-soluble anticorrosive – – – –

Caltex XLI Delo XLI Texaco XLI Havoline XLI

The mix ratio must indicate a value of 2.8 +/- 0.9 % Brix at all times. This corresponds with 5-10 % anticorrosive and 95-90 % water.

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u Remove a sample of coolant and analyse using refractometer 2710 from the Gefo Company.

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Maintenance Maintenance tasks every 2000 operating hours

Checking the mix ratio using a refractometer

Fig. 109: Gefo Refractometer 2710 1

Refractometer

2

Ocular

Test procedure u Clean cover and prism thoroughly. u Apply 1-2 of test coolant to the prism. w The test fluid is distributed by closing the flap. u Look through the ocular 2 against a bright background and focus the scale. u Adjust the visual acuity by turning the ocular 2.

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u Read off the Brix values on the blue parting line in the ocular 2.

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Maintenance Maintenance tasks every 2000 operating hours

Fig. 110: Determining of the filling amount using 1% Brix as an example 1

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2

Anticorrosive filling amount (litres) Reference lines

3 4

Refractometer readout in % Brix Amount of coolant (litres) in the cooling system

If a value of 1 % Brix is measured in the cooling system, follow reference line 2 (starting from measured value 1 Brix) downwards to the left to the vertical line for the amount of coolant in the cooling system 4 (50 litres) and from this point out to the left horizontally (2.4 litres of pure anticorrosive 1). The amount of pure anticorrosive 1 that needs to be topped up can thus be obtained in order to once again attain the required value of 2.8 Brix.

To reproduce the correct mix ratio, at least the amount (previously) determined must be drained from the cooling system. u Fill in the determined amount of pure anticorrosive. u To attain the required coolant level, refill the remainder with the previously drained coolant.

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Maintenance Maintenance tasks every 3000 operating hours

5.11 Maintenance tasks every 3000 operating hours It must be ensured that: q The diesel engine is in the maintenance position.

5.11.1 Grease the flywheel starter ring gear The maintenance cover is situated on the right-hand side of the diesel engine on the flywheel housing.

Fig. 111: Maintenance cover of starter ring gear u Remove the maintenance cover 1 from the flywheel housing.

Note u Ensure when greasing that the sensor ring gear 3 remains free of grease. u Grease the starter ring gear 2. u Remount the maintenance cover.

5.11.2 Replacing the coolant

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It must be ensured that: q The heating taps, if featured, are open. q A collecting vessel featuring the necessary volumetric capacity is on-hand. q A drainage hose is on-hand. q The necessary amount of coolant is on-hand.

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Maintenance Maintenance tasks every 3000 operating hours

Draining the coolant DANGER Hot refrigerant!

Burns. u Before opening the filler neck, allow the engine to cool. u Beware of overpressure when opening the filler neck. u Under no circumstances should the cooling system be filled when the engine is still hot.

Fig. 112: Draining the coolant u Turn the sealing cap 1 slightly in an anticlockwise direction to allow excess pressure to dissipate, then open.

CAUTION Coolant can cause injury to the eyes and lead to allergic skin reactions! u Avoid contact of coolant with skin at all costs. u Refer to the manufacturer's instructions. u When mixing coolant, always wear rubber gloves and protective glasses. u Wash out any splashes in the eyes or onto skin immediately with water. u Position a collecting vessel beneath the diesel engine. u Open the protective cap 2 from the drain valve on the radiator plate on the lefthand side of the diesel engine.

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u Screw the drainage hose onto the drain valve, the drain valve opens. u Open the drain plug on the cooler (see documentation of the machine manufacturer). w The coolant from the oil cooler housing and cooler flows into the tank. u Once the coolant has drained, unscrew the drainage hose from the drain valve. u Fit the protective cap and close the cooler again.

Filling in coolant u Fill in the ready-mixed coolant prepared in accordance with specifications in the chapter “Diesel engine coolant” via the filler neck.

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Maintenance Maintenance tasks every 3000 operating hours

u Fill cooling system to maximum level. u Fit the sealing cap on the expansion tank and close. u Start the diesel engine and allow to run warm.

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u Check the coolant level again when the diesel engine has cooled and rectify as necessary.

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Maintenance Maintenance tasks every 4500 operating hours

5.12 Maintenance tasks every 4500 operating hours It must be ensured that: q The diesel engine is in the maintenance position.

5.12.1 Replacing the foam element and the filter element of the SCR urea pump It must be ensured that: q A new foam element and filter element is on-hand. q A new drain plug is on-hand. q A new sealing ring for the filter cover is on-hand. q A collecting vessel featuring the necessary volumetric capacity is on-hand.

Fig. 113: SCR urea pump u Disconnect the electrical connection. u Place a collecting vessel beneath the SCR urea pump. u Open the bleed screw 1.

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u Unscrew the drain plug 6. u Allow the remaining reducing agent to flow into the collecting vessel. u Unscrew the filter cover 5 using a socket spanner or tube wrench. u Remove the filter element 3 and foam element 2 and dispose of in an environmentally-friendly manner (for correct procedure, see chapter “Disposing of used materials”. u Remove the old sealing ring 4. u Lubricate the new sealing ring 4 with clean water or reducing agent and fit onto the filter cover. u Insert new foam element and filter element into the filter cover.

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Maintenance Maintenance tasks every 4500 operating hours

u Insert the filter cover with fitted foam element and filter element into the filter housing. u Tighten the filter cover with 15 Nm. u Tighten the new drain plug with 2.5 Nm. u Tighten the bleed screw with 1.5 Nm. u Check for leakage loss from the priming pump. u Re-establish electrical connection. u Start the diesel engine. u Check the pump for leaks during the start sequence (priming).

Troubleshooting Leaks have been determined? u Do not start the diesel engine.

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u Rectify the leak.

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Maintenance Maintenance tasks every 10000 operating hours

5.13 Maintenance tasks every 10000 operating hours It must be ensured that: q The diesel engine is in the maintenance position.

5.13.1 Replace the heater flange It must be ensured that: q A new heater flange is on-hand.

The heater flange is installed on the right-hand side of the diesel engine, or in the air induction pipe.

Fig. 114: Removing and installing the heater flange u Switch off battery main switch if featured, and disconnect the negative cable from the battery. u Disconnect the electrical connecting cable on the heater flange.

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u Dismantle the heater flange. u Install the new heater flange. u Connect the electrical connecting cable on the heater flange, as well as the negative cable on the battery.

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Maintenance Maintenance tasks as required

5.14 Maintenance tasks as required

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It must be ensured that: q The diesel engine is in the maintenance position.

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Maintenance Check the heater flange

5.15 Check the heater flange It must be ensured that: q An ohmmeter or a multimeter is on-hand.

The heater flange (1) is installed on the right-hand side of the diesel engine or in the air induction pipe.

Fig. 115: Heater flange u Switch off battery main switch if featured, and disconnect the negative cable from the battery. u Disconnect the electrical connecting cable on the heater flange. u Connect the ohmmeter or the multimeter to the terminals and check the resistance.

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Troubleshooting A resistance value of 250 mOhm +/- 10% at 20°C has not been reached? u Replace the heater flange. u Connect the electrical connecting cable on the heater flange, as well as the negative cable from the battery.

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Maintenance Bleeding the fuel system

5.16 Bleeding the fuel system Bleeding of the fuel prefilter and fuel low-pressure system is necessary following: q Replacement of the fuel prefilter q The fuel tank being allowed to run empty q Initial start-up of the diesel engine WARNING Dirt!

Ruination of the Common Rail System. u No injection lines may be opened or loosened. u Ensure absolute cleanliness for all tasks. u Refer to the special information regarding working on the Common Rail System, see the chapter “Special notes on safety”.

It must be ensured that: q A collecting vessel for the fuel is on-hand.

WARNING Naked flames!

Fire and explosion. u When carrying out maintenance and inspection tasks on the fuel system, do not handle naked flames. u Only carry out maintenance and inspection tasks if the diesel engine has been shut down.

Procedure for bleeding the fuel system if the manual delivery pump is mounted in front of the fuel prefilter.

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u Open shut-off valve on the fuel tank if featured.

Fig. 116: Bleeding the fuel prefilter

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Maintenance Bleeding the fuel system

u Open the bleed screw 1. u Turn the marking 2a “PU” in the direction of the arrow (in an anticlockwise direction). u Continue to actuate the manual delivery pump 2b until bubble-free fuel flows out at the bleed screw 1. u Tighten the bleed screw with a tightening torque of 6 Nm.

Fig. 117: Connection MOTOR IN u Open the cap nut of the fuel supply line at connection MOTOR IN. u Continue to actuate the manual delivery pump.

If bubble-free fuel is flowing from the loosened pipe connection MOTOR IN: u Screw in the opened fuel line MOTOR IN again with the corresponding tightening torque. u Continue to actuate the hand pump until a significant resistance can be felt.

To allow start-up of the diesel engine: u Turn the “arrow” marking 2c in the direction indicated by the arrow (clockwise). u Start the diesel engine.

Troubleshooting The engine has still not started after approx. 20 seconds?

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u Wait for 1 minute.

When this action has been repeated three times: u Repeat the bleed procedure.

Procedure for bleeding the fuel system if the manual delivery pump is mounted after the fuel prefilter.

NOTICE Bleed screw on the fuel prefilter is open.

System is not bled properly, whereby not all of the air is dissipated at the prefilter. u Do not open the bleed screw at the fuel prefilter.

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Maintenance Bleeding the fuel system

u Open the cap nut of the fuel supply line at connection MOTOR IN.

Fig. 118: Manual delivery pump u Turn the marking 2a “PU” in the direction of the arrow (in an anticlockwise direction).

Fig. 119: Connection MOTOR IN If bubble-free fuel is flowing from the loosened pipe connection MOTOR IN: u Screw in the opened fuel line MOTOR IN again with the corresponding tightening torque. u Continue to actuate the hand pump until a significant resistance can be felt.

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u Actuate the manual delivery pump 2b.

Maintenance Bleeding the fuel system

To allow start-up of the diesel engine: u Turn the “arrow” marking 2c in the direction indicated by the arrow (clockwise). u Start the diesel engine.

Troubleshooting The engine has still not started after approx. 20 seconds? u Wait for 1 minute.

When this action has been repeated three times: u Repeat the bleed procedure.

Note

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u The low-pressure circuit (NDK) of the engine is bled by permanently installed restrictor bores, no other additional measures are necessary.

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Maintenance Replacing the dry air filter main element

5.17 Replacing the dry air filter main element

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Correct procedure for replacing the dry air filter main element, see documentation of the machine manufacturer.

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Maintenance Replacing the dry air filter safety element

5.18 Replacing the dry air filter safety element

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Correct procedure for replacing the dry air filter main element, see documentation of the machine manufacturer.

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Maintenance Transport and storage

5.19 Transport and storage 5.19.1 Lifting gear DANGER Falling load!

Risk of fatalities. u Only use the transport devices for transport of the engine, and do not use any other accessories. u Standing or working beneath suspended loads is prohibited.

To lift the diesel engine, hook the correct lifting gear onto the transportation devices provided.

Fig. 120: Lifting gear

The LIEBHERR diesel engine has been preserved from the date on which it was declared ready for shipment, with normal storage in a dry, well-ventilated area, the preservation protection period is 6 months.

If the diesel engine is additionally covered with plastic sheeting, it may also be left out in the open for up to a month.

The cover must be watertight and be wrapped loosely around the diesel engine in order that the air can circulate around the diesel engine, thus preventing any condensation forming.

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5.19.2 Storage up to 6 months

Maintenance Transport and storage

If the aforementioned measures are not strictly adhered to, whereby the preserved diesel engine is subjected to unfavourable conditions (left out in the open for lengthy periods of time or being stored in damp, poorly-ventilated areas etc.) a shorter preservation protection period must be estimated.

5.19.3 Storage for between 6 and 24 months

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For storage between 6 and 24 months, please consult LIEBHERR Services or a LIEBHERR authorised dealer.

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Maintenance

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Transport and storage

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6 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”).

6.2.1 EPA/CARB Fuel label The engine must be operated with “ULTRA LOW SULFUR FUEL ONLY”.

Within the proximity of the filler neck the following label with the remark “ULTRA LOW SULFUR FUEL ONLY” must be attached in a such way that it is well visible and permanently readable when refuelling.

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Fig. 121: Fuel label “ULTRA LOW SULFUR FUEL ONLY” 10315343

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Supplemental Information USA Emission control warranty statement warranty rights and obligations

6.3 Emission control warranty statement warranty rights and obligations In the United States of America, new nonroad engines must be designed, built and equipped so they conform at the time of sale to the ultimate purchaser with the requirements of US EPA CFR Part 1039 and with all applicable regulations adopted by the Air Resources Board pursuant to its authority for Title 13, California Code of Regulations, Section 2425. Liebherr Machines Bulle S.A. (Liebherr) warrants the emission control system on its engines for the periods of time listed below provided there has been no abuse, neglect, improper maintenance or unauthorised modification on your engine.

The emission control system may include parts such as the fuel injection and the air induction system. Also included may be hoses, connectors and other emissionrelated assemblies.

Where a warrantable condition exists, an authorised Dealer of Liebherr Construction Equipment Co. (LCE), a company of Liebherr Mining & Construction Equipment, Inc., on behalf of Liebherr, will repair the nonroad engine at no cost to the machine owner, including diagnosis, parts and labour.

6.3.1 Manufacturer's warranty coverage All emission related parts of 2011 and later nonroad engines, which are purchased in the United States of America, are warranted for a period of five years or 3,000 hours of operation, whichever occurs first. If any emissionrelated part on the engine is defective, the part will be repaired or replaced by an authorised Liebherr Dealer.

– A nonroad compression-ignition engine owner is responsible for the performance of the required maintenance listed in the machine’s Operation & Maintenance Manual. Liebherr recommends that the owner maintains a log book and retains all receipts covering maintenance on the nonroad engine, but Liebherr cannot deny warranty solely for the lack of receipts or for failure to ensure the performance of all scheduled maintenance.

– Liebherr may deny warranty coverage if the nonroad compression-ignition engine or a part thereof has failed due to abuse, neglect, improper maintenance, or unapproved modifications.

– The nonroad compression-ignition engine is designed to operate on Ultra low sulphur diesel fuel only. Use of any other fuel may result in the engine no longer operating in compliance with US Environmental Protection Agency (EPA) and California Air Resources Board (ARB) emission requirements.

– The owner is responsible for initiating the warranty process. The US Environmental Protection Agency and California Air Resources Board suggests that nonroad engines or machines be made available to an authorised Liebherr Dealer to perform warranty service on behalf of Liebherr as soon as a problem arises. The warranty repairs should be completed by the authorised Dealer as expeditiously as possible.

Questions in regard to warranty rights and responsibilities or the location of the nearest authorised Liebherr Dealer should be directed to Liebherr service department in Newport News, VA, (757) 245-5251.

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6.3.2 Owner's warranty responsibilities

Supplemental Information USA Emission control warranty statement warranty rights and obligations

6.3.3 Warranty coverage Liebherr warrants any 2011 and later model year nonroad diesel engine certified for sale and registered in the United States of America and the State of California is designed, built, and equipped so as to conform to all applicable regulations adopted by the EPA and ARB. Liebherr warrants that such engine is free from defects in materials and workmanship which cause the failure of a warranted part to be identical in all material respects to the part as described in the engine manufacturer’s application for certification for a period of five (5) years or 3,000 hours of operation, whichever occurs first. The warranty period begins on the date the engine or machine is delivered to an ultimate purchaser. Liebherr also warrants that any part that is on the warranted emission parts list of this warranty and installed as original equipment is free from defects in material and workmanship, which would cause this engine not to be in compliance with the emission standards adopted by the EPA and ARB for five (5) years or 3,000 hours, whichever occurs first. Except for any warranted part that is scheduled for replacement as required maintenance, if any warranted part fails during the period of warranty coverage, the part will be repaired or replaced by LCE at no charge to the owner by any authorised Liebherr Dealer. Any such part repaired or replaced during the warranty period will be warranted for the remaining warranty period. 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 at no charge to the owner at any authorised Liebherr Dealer. Any such part repaired or replaced prior to the first scheduled replacement point will be warranted for the remainder of the period prior to the first scheduled replacement point.

The owner will not be charged for diagnostic labour that leads to the determination that a warranted part is in fact defective, so long as such diagnostic work is performed by an authorised Liebherr Dealer. If a warranted part fails because of a defect, Liebherr will repair or replace it at any authorised Liebherr Dealer. Any other engine components damaged by the failure of a warranted part will also be repaired or replaced at no charge to the owner.

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6.3.4 Warranted parts Following are the only parts warranted under this Emission Control Warranty.

1. Fuel Injection System 2. Intake Manifold 3. Turbocharger System 4. Charge Air Cooling System 5. Exhaust Gas Recirculation (EGR) System 6. EGR Control System 7. Exhaust Manifold 8. Diesel Particulate Filter System 9. Diesel Oxidation Catalyst 10. Fuel Additive Devices 11. Selective Catalyst Reduction 12. Reductant Containers 13. Electronic Control Unit, Sensors, Solenoids and Wiring Harnesses 14. Emission Control Information Label

Exclusions This warranty does not cover: – Malfunctions in any part caused by abuse, misuse, alterations, tampering, disconnection, or improper or inadequate maintenance.

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Supplemental Information USA Emission control warranty statement warranty rights and obligations

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– 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 replacement part may be used in the performance of any maintenance or repairs. However, the manufacturer is not liable for non-manufacturer parts.

– Any damages resulting from use of non-genuine Liebherr parts.

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Checking the oil sump, engine mount and diesel engine brackets for secure seating 81 Checking the ribbed V-belt 76 Checking valve clearance and adjusting with engine auxiliary brake system (ZBS) 84 Cleaning the dust-discharge valve of the air filter 70 Cold start package 16 Control and operating elements 31 Coolant — mix ratio 59 Coolant for diesel engine 58 Coolant pump D934 18 Coolant pump D936 / D946 18 Coolant thermostat 18 Cooling 15 Cooling system 52 Crankcase 15 Cylinder designation, rotational direction 14 Cylinder head - valves 52 Cylinder head with engine auxiliary brake system (ZBS) 18 Cylinder head, standard 17

Index

A Additional rules and regulations 22 Adjusting the correct anticorrosive/antifreeze concentration 90 Adjusting the exhaust valve clearance 86 Air compressor 16 Air filter 53 Air-conditioning compressor 16 Availability 37

B

D

Bleeding the fuel prefilter 69 Bleeding the fuel system 102

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C Changing diesel engine oil and replacing the oil filter 71 Check low-pressure display of the air filter 69 Check the coolant level 67 Check the cooling and heating systems for sound condition and for leaks 78 Check the engine oil level 66 Check the flap of the diesel engine brake 71 Check the heater flange 101 Checking / draining the water separator of the fuel prefilter 67 Checking and adjusting intake valve clearance 84 Checking and adjusting valve clearance 82 Checking and adjusting valve clearance standard 82 Checking and replacing the ribbed V-belt 76 Checking anticorrosive / antifreeze concentration in the coolant 90 Checking exhaust valve clearance 85 Checking induction and exhaust gas system for sound condition and for leaks 78 Checking lubrication system and fuel system for leaks and for sound condition 79 Checking sensors, actuators, cable fittings and plugs for sound condition 80 Checking the anticorrosive/antifreeze concentration 90 Checking the batteries and cable connections 79 Checking the control unit mounting for sound condition 79 Checking the mix ratio using a refractometer 92

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Design features 14 Designation of warning information 21 Diesel engine 17, 52 Diesel engine brake and auxiliary brake system 16 Diesel engine characteristics 14 Diesel engine design 14 Diesel engine number 13 Diesel engine type identification plate 12 Diesel fuel at low temperatures (winter operation) 56 Diesel fuel lubricity 56 Diesel fuels 55 Disposal 36 Disposing of fuels and lubricants 29 Disposing of used materials 55 Drain water and sediment in the fuel tank 70 Draining the coolant 95 Draining the diesel engine oil 72 Draining the fuel pre-filter 68 Drive control 15

E Ease of ignition 56 Electrical system 53 Electronic diesel engine regulation 15 Electronic sensors on the engine side 16 Emission control warranty statement warranty rights and obligations 112 Engine 15 Engine classification 11 Engine control unit identification plate 13 Environmental-protection guidelines 55 EPA/CARB Fuel label 111 EU strategies (Stage IIIB) 38

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Index

F Faults - Cause - Remedy 45 Filling amounts 54 Filling diesel engine oil 74 Filling in coolant 95 Filling in fuels 32 Flywheel housing 19 Fuel system 52 Fuels and lubricants 55 Further designations 21

G General notes on safety 22 General recommendations 58 Generator 18 Grease the flywheel starter ring gear 94

H Handling fuels and lubricants 55

I Index 115 Indicator lamps and warning lamps 37 Initial start-up / test run 32 Injection system 15

L Lifting gear 108 Lube oil quality 56 Lube-oil change intervals 57 Lube-oil viscosity 57 Lube-oils for the diesel engine 56 Lubrication 15

M Maintenance 51 Maintenance and inspection chart 51 Maintenance tasks (daily), every 10 operating hours 66 Maintenance tasks (weekly) every 50 operating hours 70 Maintenance tasks as required 100 Maintenance tasks every 1000 operating hours 81 Maintenance tasks every 10000 operating hours 99 Maintenance tasks every 2000 operating hours 90 Maintenance tasks every 3000 operating hours 94 Maintenance tasks every 4500 operating hours 97 Maintenance tasks, every 500 operating hours 71

Malfunctions 45 Manufacturer's warranty coverage 112 Measures for safe maintenance 24 Mounting options for pumps 16

N Notes on safety 21 Notes on the prevention of crushing and burns 23 Notes on the prevention of fire and explosions 23

O Observe safety precautions when starting 23 Observe the safety precautions for diesel engines featuring electronic control units 25 Operation 32 Operation, Servicing 31 Overview of assembly 9 Owner's warranty responsibilities 112

P Particularly hazardous 27 Permissible ready-mixed anticorrosive/antifreezes 60 Permitted anticorrosive / antifreeze 59 Permitted anticorrosive / antifreeze (inhibitors) without antifreeze 60 Preparations prior to initial start-up 32 Preparatory maintenance tasks 65 Product description 9

R Reducing agent 35 Replace the heater flange 99 Replacing ribbed V-belts 77 Replacing the coolant 94 Replacing the dry air filter main element 106 Replacing the dry air filter safety element 107 Replacing the foam element and the filter element of the SCR urea pump 97 Replacing the fuel fine-filter 88 Replacing the fuel prefilter element 87 Replacing the oil filter 73 Replacing the oil separator filter element 75

S Safety and emergency run program for diesel engines featuring electronic control units 26 SCR-System 53 Special equipment for the diesel engine 16 Special notes regarding tasks on the Common Rail System 26 Special tools for maintenance tasks 62 Specification 35, 55 Start the diesel engine. 33

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Exclusions 113 Exhaust gas after-treatment system (SCR) 29, 35 Explanation of type description 11

Index Starter 18 Starting in frosty temperatures 34 Storage for between 6 and 24 months 109 Storage suitability / Temperature-resistance 36 Storage up to 6 months 108 Sulphur content in the diesel fuel 56 Supplemental Information USA 111 Switching off the diesel engine. 34

T Table for filling amounts 54 Tasks to be performed following the test run 33 Technical data 17 Technical description 9 Test run 32 Transport and storage 108

U US-EPA/CARB strategies (Tier4i) 40 Utilisation 37 Utilisation / handling 36 Utilisation of anticorrosive without antifreeze 91 Utilisation of DCA 4 91 Utilisation of water-soluble anticorrosive 91

V Visual inspection (leaks, contamination, damages) 67

W

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Warning and malfunction strategies 37 Warranted parts 113 Warranty coverage 113 Water (fresh water) 58

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