LIEBHERR > Diesel engines

D 914 / 916 T, TI
D 924 / 926 T>E, TI, TI>E

Operating Instructions
Betriebsanleitung
0
 LIEBHERR
DIESEL ENGINE

D 914 / 916 / 924 / 926 T, TI, TI>E

Operating instructions

BAL >No. 14105>10>02

pages : 1 up to 59

LIEBHERR>WERK EHINGEN GmbH, Postfach 1361, D>89582 Ehingen / Donau

Telefon (07391) 5 02>0, Telefax (07391) 5 02>33 99

www.lwe.liebherr.de, E>mail: info@lwe.liebherr.com

1
FOREWORD 021142>01

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FOREWORD 021142>01

This operating manual comprises the most important points for proper operation and service of LIEBHERR
diesel engines.

We urgently advise that the specified maintenance work be carried out carefully and punctually. This will
ensure that the engine is fully operational at all times.

You will appreciate that we cannot consider guarantee claims for damage caused by improper operation or
inadequate maintenance.

IMPORTANT: LIEBHERR will annul without notice all obligations undertaken by LIEBHERR
and/or its authorized dealers, such as guarantee agreements, service contracts etc.,
if any spare parts other than original parts manufactured LIEBHERR or sold by
LIEBHERR are used for maintenance and repair.
We recommend that the sales and service offices (also Liebherr Bagger) listed in the
chapter AUTHORIZED DEALERS be consulted for maintenance and repair of
LIEBHERR engines.

The technical data, illustrations and dimensions provided in this manual are subject to alteration, and cannot
be used as a basis for claims of any nature. We reserve the right to undertake improvements to the engine
design without changing these instructions.

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CONTENTS

183628

4
CONTENTS

1.00 DESCRIPTION OF ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.00 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.00 LUBRICANTS AND SERVICE FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.01 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.02 MAINTENANCE WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.03 CERTIFICATION OF COMPLETED MAINTENANCE WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.00 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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1.00 DESCRIPTION OF ENGINE 021143>05

Technical description

Engine design
Vertical, water>cooled four>stroke in>line engines using the Liebherr direct injection process. Models with the
supplementary designation "T" are equipped with an exhaust>gas turbocharger.

Characteristics
A simple, sturdy basic construction and generous dimensions provide the foundation for high operating safety
and long service life. Low fuel consumption, low noise emission and excellent fumes are achieved through a
combustion process which is specially adapted to the engine requirements. The overall cost> efficiency of the
engines is enhanced by the low maintenance requirements of the easily>accessible components and by a diverse
range of optional accessories.

Power transmission
In the case of the the 4>cylinder engines, steel crankshaft with 5 bearings, inductively hardened bearing
surfaces and 8 solid forged counterweights.
In the case of the 6>cylinder engines, steel crankshaft with 7 bearings, 12 solid forged counterweights and a
pendulum damper at the front end of the crankshaft.
Forge>pressed connecting rod.
Leaded bronze trimetal sliding bearings for piston, connecting rod and crankshaft assembly, three>ring piston
made of aluminium alloy with ring support and combustion recess in the piston base.
Exchangeable, wet cylinder liners.

Housing
Cylinder block and crankcase accommodated in one unit made of alloy cast>iron. Single cylinder heads with
integral intake guide channel and detachable valve seat rings and valve stem guides. The rear flywheel casing,
front unit support and aluminium oil sump on the underside form the engine boundary.

Engine timing
Per cylinder one intake and exhaust valve respectively, located in the cylinder head (OHV). Actuated by steel
camshaft with 5 or 7 bearings via chilled iron tappet, push rod and rocker arm. Drive by camshaft, fuel>injection
pump, lubricating oil pumps, air compressor, water pump, radiator ventilator and auxiliary hydraulic pumps
from the crankshaft via nitride steel gearwheels in the unit support at the engine front end.

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1.00 DESCRIPTION OF ENGINE 021143>05

Lubrication
Forced>feed lubrication through gear pump for crankshaft, connecting rod and camshaft bearings, as well as
piston pin bearing bush, tappet and rocker arm.
Oil filtration by means of double>paper throw>away cartridge filter in the full>flow circuit. Adjacent units such
as fuel>injection pump and air compressor are connected to the engine lubricating oil circuit. Plate oil coolers
organically integrated in the coolant water stream are combined with the oil filter in a single unit.
Large>sized oil sumps with all>round 100% tilting capacity.

Cooling
Double>thermostatically regulated fluid cooling with centrifugal pump.
Each cylinder unit supplied individually by means of distributor channels integrated in the crankcase.
Water>bearing components are linked by plug>in elements and rubber ring seals. The inside of the piston base is
continuously cooled through oil sprayed from the engine lubricating oil circuit.

Fuel>injection unit and regulation

Maintenance>free Bosch in>line fuel>injection pump, supply pump and fuel filter, Bosch four>hole nozzles.
Mechanical governor Bosch > RSV.

Electrical equipment
Starter and three>phase dynamos, 24 Volt.

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1.00 DESCRIPTION OF ENGINE 021143>05

186021

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1.00 DESCRIPTION OF ENGINE 021143>05

Designations of engine type:

Serial numbers such as D 914 / 924 / 916 / 926 T, TI, TI>E designate water>cooled 4 and 6 cylinder in>line
engines.

Engine rating plate:

Starting from the flywheel, the rating plate is mounted on the right>hand side of the crankcase above the
injector pump.

Data:
TYP = For example: D 926 TI>E
MOT.NR. = Engine serial number
CODE = For additional data, if required
KW = Engine output in kW
1/min = Rated engine speed
LIEFERUMFANG = Identification number of engine configuration

Engine identification

D = Diesel engine

91 = Bore a 120 mm
92 = Bore a 122 mm

4 = Number of cylinders = 4 cylinders

6 = Number of cylinders = 6 cylinders

TI>E = Additional identification

Additional descriptions: NA = Naturally aspirated engine

T = Turbocharged
TB = Lightly turbocharged
TI = Turbocharged and intercooled

E = Exhaust optimized

Valve adjustment: E = Intake valve

A = Exhaust valve

4>cyl. in>line engine 6>cyl. in>line engine

overlap adjustment overlap adjustment

4 1 6 1
2 3 2 5
1 4 4 3
3 2 1 6
5 2
3 4

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1.00 DESCRIPTION OF ENGINE 021143>05

10
1.00 DESCRIPTION OF ENGINE 021143>05

D 914 / 916 T

1 Air compressor
2 Oil separator
3 Crankshaft belt pulley
4 Coolant temperature sensor
5 Oil pressure sensor (with warning contact)
6 Starter motor
7 Cooling water circulating pump
8 Fan / Visco fan
9 Generator
10 Double thermostat
11 Exhaust>gas turbocharger

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1.00 DESCRIPTION OF ENGINE 021143>05

12
1.00 DESCRIPTION OF ENGINE 021143>05

D 914 / 916 T

1 Dip stick
2 Cylinder head cover
3 Oil filter cartridges
4 Fuel>injection pump
5 Oil filler neck
6 Combustion air suction pipe
7 Fuel filter cartridges
8 Fuel preliminary filter
9 Fuel supply pump
10 Cold start solenoid valve
11 Cold start flame glow plug
12 Oil temperature sensor for flame starting device
13 Rating plate

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1.00 DESCRIPTION OF ENGINE 021143>05

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1.00 DESCRIPTION OF ENGINE 021143>05

TECHNICAL DATA D 914 T D 914 TI

Exhaust emission > >

Model 4>cyl. turbocharged 4>cyl. turbocharged

Bore > diameter a mm 120 120

Piston stroke mm 135 135

Displacement, total cm3 6100 6100

Firing order 1>3>4>2 1>3>4>2

Compression ratio 15,9 : 1 15,9 : 1

Compression pressure at starter

speed bar 19 ... 27 19 ... 27

Direction of rotation, when viewed

looking at the flywheel left left

Flywheel housing SAE 2 SAE 2

Cooling Water circulation Water circulation

Fuel>injection pump Type in>line injection pump in>line injection pump

Weight of engine, dry, without

cooling system kg approx. 710 approx. 710

ENGINE TUNE>UP
SPECIFICATIONS D 914 T D 914 TI

Valve clearance, Intake

cold mm 0,20 0,20

Valve clearance, Exhaust

cold mm 0,25 0,25

Begin of delivery ∞KW v OT 20∞ ± 1∞ 20∞ ± 1∞

Opening pressure of fuel injector

nozzles
new bar 225 +8 225 +8
in operation bar 217 +8 217 +8

according to according to
OUTPUT RATINGS DIN 6271 ISO 3046.1

Engine output kW 110 125

Rated speed (RPM) min>1 2000 1800

RPM (med. >max.) min>1 1400 1300

Max. torque Nm 593 705

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1.00 DESCRIPTION OF ENGINE 021143>05

D 916 TI D 916 TI
TECHNICAL DATA D 916 T in the crane carrier in the superstructure

Exhaust emission > EURO 1 >

Model 6>cyl. turbocharged 6>cyl. turbocharged 6>cyl. turbocharged

Bore > diameter a mm 120 120 120

Piston stroke mm 135 135 135

Displacement, total cm3 9200 9200 9200

Firing order 1>5>3>6>2>4 1>5>3>6>2>4 1>5>3>6>2>4

Compression ratio 15,9 : 1 15,9 : 1 15,9 : 1

Compression pressure at starter

speed bar 19 ... 27 19 ... 27 19 ... 27

Direction of rotation, when viewed

looking at the flywheel left left left

Flywheel housing SAE 2 SAE 2 SAE 1

Cooling Water circulation Water circulation Water circulation

Fuel>injection pump Type in>line injection pump in>line injection pump in>line injection pump

Weight of engine, dry, without

cooling system kg approx. 900 approx. 900 approx. 900

ENGINE TUNE>UP D 916 TI D 916 TI

SPECIFICATIONS D 916 T in the crane carrier in the superstructure

Valve clearance, Intake

cold mm 0,20 0,20 0,20

Valve clearance, Exhaust

cold mm 0,25 0,25 0,25

Begin of delivery ∞KW v OT 20∞ ± 1∞ 15∞ ± 1∞ 20∞ ± 1∞

Opening pressure of fuel injector

nozzles
new bar 225 +8 225 +8 225 +8
in operation bar 217 +8 217 +8 217 +8

according to according to according to

OUTPUT RATINGS DIN 6271 ECE R 24/03 ISO 3046.1

Engine output kW 170 180 182

Rated speed (RPM) min>1 2100 2100 1800

RPM (med. >max.) min>1 1300 1300 1400

Max. torque Nm 940 1020 1077

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1.00 DESCRIPTION OF ENGINE 021143>05

D 924 T>E D 924 TI>E

TECHNICAL DATA in the superstructure in the superstructure

Exhaust emission EUROMOT 1 EUROMOT 1

Model 4>cyl. turbocharged 4>cyl. turbocharged

Bore > diameter a mm 122 122

Piston stroke mm 142 142

Displacement, total cm3 6640 6640

Firing order 1>3>4>2 1>3>4>2

Compression ratio 17,2 : 1 17,2 : 1

Compression pressure at starter

speed bar 20... 28 20... 28

Direction of rotation, when viewed

looking at the flywheel left left

Flywheel housing SAE 2 SAE 1

Cooling Water circulation Water circulation

Fuel>injection pump Type in>line injection pump in>line injection pump

Weight of engine, dry, without

cooling system kg approx.740 approx.740

ENGINE TUNE>UP D 924 T>E D 924 TI>E

SPECIFICATIONS in the superstructure in the superstructure

Valve clearance, Intake

cold mm 0,25 0,25

Valve clearance, Exhaust

cold mm 0,30 0,30

Begin of delivery ∞KW v OT see engine rating plate see engine rating plate

Opening pressure of fuel injector

nozzles 225 +8 225 +8
new bar 217 +8 217 +8
in operation bar

according to according to
OUTPUT RATINGS ISO 9249 ISO 9249

Engine output kW (PS) 120 149

Rated speed (RPM) min>1 1800 1800

RPM (med. >max.) min>1 1200 1200

Max. torque Nm 718 891

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1.00 DESCRIPTION OF ENGINE 021143>05

D 926 TI D 926 TI>E

TECHNICAL DATA in the crane carrier in the crane carrier

Exhaust emission EURO 2 EURO 2

Model 6>cyl. turbocharged 6>cyl. turbocharged

Bore > diameter a mm 122 122

Piston stroke mm 142 142

Displacement, total cm3 9960 9960

Firing order 1>5>3>6>2>4 1>5>3>6>2>4

Compression ratio 16 : 1 17,2 : 1

Compression pressure at starter

speed bar 19 ... 27 20... 28

Direction of rotation, when viewed

looking at the flywheel left left

Flywheel housing SAE 2 SAE 2

Cooling Water circulation Water circulation

Fuel>injection pump Type in>line injection pump in>line injection pump

Weight of engine, dry, without

cooling system kg approx. 900 approx.900

ENGINE TUNE>UP D 926 TI D 926 TI>E

SPECIFICATIONS in the crane carrier in the crane carrier

Valve clearance, Intake

cold mm 0,20 0,25

Valve clearance, Exhaust

cold mm 0,25 0,30

Begin of delivery ∞KW v OT 13∞ ± 1∞ see engine rating plate

Opening pressure of fuel injector

nozzles 225 +8 225 +8
new bar 217 +8 217 +8
in operation bar

according to according to
OUTPUT RATINGS ECE R 24/03 ECE R 24/03

Engine output kW (PS) 230 230

Rated speed (RPM) min>1 2100 2100

RPM (med. >max.) min>1 1550 1400

Max. torque Nm 1170 1190

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1.00 DESCRIPTION OF ENGINE 021143>05

D 926 TI D 926 T>E D 926 TI>E

TECHNICAL DATA in the superstructure in the superstructure in the superstructure

Exhaust emission > EUROMOT 1 EUROMOT 1

Model 6>cyl. turbocharged 6>cyl. turbocharged 6>cyl. turbocharged

Bore > diameter a mm 122 122 122

Piston stroke mm 142 142 142

Displacement, total cm3 9960 9960 9960

Firing order 1>5>3>6>2>4 1>5>3>6>2>4 1>5>3>6>2>4

Compression ratio 16 : 1 17,2 : 1 17,2 : 1

Compression pressure at starter

speed bar 19 ... 27 20... 28 20... 28

Direction of rotation, when viewed

looking at the flywheel left left left

Flywheel housing SAE 1 SAE 1 SAE 1

Cooling Water circulation Water circulation Water circulation

Fuel>injection pump Type in>line injection pump in>line injection pump in>line injection pump

Weight of engine, dry, without

cooling system kg ca. 900 ca.900 ca.900

ENGINE TUNE>UP D 926 TI D 926 T>E D 926 TI>E

SPECIFICATIONS in the superstructure in the superstructure in the superstructure

Valve clearance, Intake

cold mm 0,20 0,25 0,25

Valve clearance, Exhaust

cold mm 0,25 0,30 0,30

Begin of delivery ∞KW v OT 20∞ ± 1∞ see engine rating plate see engine rating plate

Opening pressure of fuel injector

nozzles 225 +8 225 +8 225 +8
new bar 217 +8 217 +8 217 +8
in operation bar

according to according to according to

OUTPUT RATINGS ISO 9249 ISO 9249 ISO 9249

Engine output kW (PS) 218 170 224

Rated speed (RPM) min>1 1800 1800 1800

RPM (med. >max.) min>1 1400 1200 1200

Max. torque Nm 1282 991 1414

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2.00 ENGINE OPERATION 021144>03

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2.00 ENGINE OPERATION 021144>03

First>time operation

Trial run after maintenance or repair work

Do not run the engine at full power, increase speed gradually up to 3/4 if the maximum capacity until the
operating temperature is reached.

Work during and after the trial run

> Refill fuels

> Check engine for leaks
> Check tube connections, hose clamps and pipe connections of whole unit for leaks and tightness. Tighten if
necessary.
> In the case of supercharger engines, check the oil feed and return lines also.
> Check that any mountings attached to the engine are firmly in position, and tighten the fastening screws on
the exhaust elbow, engine bearings, water pump, starter, air compressor etc.

Running>in

New and completely overhauled engines should be run at full capacity only for the shortest possible periods
during the initial 50 operating hours. Engines which have been fitted in vehicles should be carefully run>in for
the first 2000 km, with a maximum of 3/4 of the maximum speed in each gear (engine speed = 1900/min). It is
crucial for the service life, operating safety and efficiency of the engine that it is not excessively strained during
the running>in period. Observe the maintenance tasks listed in the maintenance chart.

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2.00 ENGINE OPERATION 021144>03

Operation

Starting and stopping

For starting the engine when external temperatures are below 0 ∞C, see section headed "Winter operation".

Open cut>off valve (if fitted) at fuel tank. Insert ignition key (see Device Operating Instructions). The battery
charge indicator lamp must light up. Start the engine by turning the ignition key without depressing the
accelerator pedal.

If the engine fails to start after approx. 5 seconds, slowly press the accelerator pedal right down. If this starting
procedure is not successful within 20 seconds, interrupt the procedure and wait 1 minute before repeating. The
starter can be operated 3 times per starting procedure for a duration of 20 seconds, with a break of one minute
between each operation. Once the motor has started, immediately check the oil pressure indicator. If no oil
pressure is indicated, switch off the engine immediately and look for the source of the fault. If the engine is
warm, start without depressing the accelerator. This will avoid soot emission.

CAUTION: The three>phase generator is essentially different from the d.c. generator in its
operating characteristics. For this reasons, the following points must be observed:

1. During operation, the three>phase generator must be connected to the batteries

always. As long as the engine is running, it is therefore not permissible to remove
or exchange any of the generator cables, battery pole terminals or the plug
connector of the controller.
2. The batteries may be charged with a rapid charging set only if the positive and
negative terminals have been slackened or detached.
3. If working with an electric welder, the earth terminal must be directly connected
with the part to be welded. Remove the positive and negative terminals of the
battery.

Stopping the engine

Relieve the engine, gradually decreasing the speed with the speed>adjustment lever so that the coolant is not
heated up, then briefly run the engine at idle speed. This point is particularly important in the case of turbo
engines, since it allows the the turbo>supercharger, which is running at high speed, some time to run down. If
the engine is stopped abruptly, the turbo>supercharger will continue to run for some time with no oil supply.

To stop the engine;

a) shift the speed>adjustment lever to "Stop"

b) actuate the shutdown solenoids (depending on engine model).

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2.00 ENGINE OPERATION 021144>03

Operation

Monitoring instruments, such as the oil pressure gauge, telethermometer, tachmometer etc., must be checked
regularly.

From time to time, check the fuel, lubricating oil and coolant lines, as well as the suction and exhaust gas lines,
for leaks.

During continuous operation, check the lubricating oil level in the oil sump at 10 hour intervals with the
engine at a standstill. If necessary, refill oil. The dip stick is calibrated to the normal fitting position of the
engine.

Check the vacuum indicator for the dry>air filter. If the red field in the vacuum indicator is visible, it is
necessary to clean the filter element. (See Maintenance of dry>air filter).

See "Technical data" for full load speed. During crane operation, the lowest permissible continuous speed is
1200/min; lower speeds are permissible for brief periods only.

Fuel level be careful not to run the fuel tank dry, otherwise residual dirt will be drawn in and the fuel system
will have to be cleaned and bled as a result.
From time to time, drain the fuel tank of any water and other contamination which may have deposited on the
tank base.

Stop the engine immediately if:

> oil pressure is dropping, or fluctuating severely

> performance and speed drop without adjustment of the controller adjustment lever position
> exhaust is smoking excessively
> coolant water and oil temperature are increasing
> abnormal noises occur in the engine or turbo>supercharger

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2.00 ENGINE OPERATION 021144>03

Operation in winter

When the cold season begins, the following instructions for fuels and starting should be observed:

Fuel:
Fuel see chapter "SERVICE FLUIDS".

lubricating oil:
If the engine is not equipped with an oil preheating facility and temperatures below O ∞C may be expected,
exchange the lubricating oil for the less viscous winter oil before the cold season begins.
See chapter "SERVICE FLUIDS"

Coolant:
Due to the danger of freezing, operation in winter without antifreeze in the cooling water is unacceptable.
For corrosion preventive the antifreeze has to remain in the cooling system throughout the year.
Before and during the winter period, the coolant should be checked for sufficient antifreeze and frost resistance.
If necessary, add antifreeze.
See chapter "SERVICE FLUIDS"

Batteries
Pay particular attention to the batteries during the cold months of the year. Attempt to maintain a full battery
charge through careful maintenance and low power consumption. The starting capacity is reduced considerably
during cold weather; e.g. at a temperature of >10∞ C, approx. only 60% of normal capacity is available. For this
reason, batteries should be stored if possible in a heated room when the engine is not in use.

Starting procedure at external temperatures below >25 ∞C.

Under extremely low temperature conditions, the engine must be preheated to ensure that it can start and that
the supply of lubricating oil is available. Only engines which are intended to be operated in extremely cold
regions are equipped (at the customer's request) with connectors for preheating devices.
> Information is available from Liebherr>Werk Ehingen

Starting procedure at external temperatures below 0 ∞C.

> see below

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2.00 ENGINE OPERATION 021144>03

Operation in winter

Starting the engine with the flame glow starting device

Always use the flame glow starting device to start the engine when the temperature is below the freezing point.
Ensure that a lengthy preheating time is observed. This will not only reduce the starting limit temperature, but
also facilitate starting at temperatures actually requiring no starting aid. Afterignition to prevent starting soot
emission is also possible if the start has been carried out with the flame starting device ("preheating") from the
outset.

The flame starter device heats the combustion air by burning small quantities of fuel by means of a flame glow
plug located at the beginning of the suction tube. The flow of fuel from the injector pump is regulated by an
electronic control unit through a solenoid valve.

Note: a) The flame starting device is automically switched off when the engine water temperature
is above +20 ∞C.
b) The preheater indicator lamp does not light up in the event of a flame glow plug failure.

Starting procedure at external temperatures below 0 ∞C

1. Preheating

The preheating time of approx. 40>50 seconds begins when the ignition starter switch is moved to position
"1" (Travel). A light (on the instrument panel) lights up to indicate to the driver that the preheating is
taking place.

If the engine is started during the preheating time, the preheating is automatically interrupted.
If so, repeat the preheating procedure.

2. Starting engine

The indicator lamp (on the instrument panel) extinguishes after the preheating time, and a start readiness
period of approx. 30 seconds now commences. The engine is started by turning the starter ignition switch to
position "2" (Start).

If the driver does not start the engine during the start readiness time, the start readiness lapses
automatically.
If so, repeat steps 1. and 2.

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3.00 LUBRICANTS AND SERVICE FLUIDS 021852>02

Engine oils

1. Oil change intervals

Oil change intervals Oil change intervals

Naturally aspirated engine Turbocharged engine

Operating cond. Sulfur content of Oil / Grade Oil / Grade Oil / Grade Oil / Grade
ambient temp. fuel CC CF>4/CF/CE/D4 CF>4/CF/CE/D4 SHPD / D5

to >10 ∞C (14 ∞F) up to 0.5% 250 hrs. 500 hrs. 250 hrs. 500 hrs.

to >10 ∞C (14 ∞F) above 0.5% 125 hrs. 250 hrs. 125 hrs. 250 hrs.

below >10 ∞C (14 ∞F) up to 0.5% 125 hrs. 250 hrs. 125 hrs. 250 hrs.

below >10 ∞C (14 ∞F) above 0.5% > 125 hrs. > 125 hrs.

2. Oil Quality / Grade

CC / CF>4 / CF / CE : API classification (American Petroleum Institute)

D4 / D5 : ACEA (CCMC) Association des Constructeurs Europ±ens de l'Automobile

SHPD : Super High Performance Diesel Oil

CC : MIL>L>2104B / MIL>L>46152B / MIL>L>46152D

CF>4 / CF / CE / D4 : MIL>L>2104E

3. Oil viscosity







































 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

















































































































































SAE 





































 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 



























































































 





20


W 
 > 20 









































































































































































































 




































































































 SAE 30 






















































































































































































 














































∞C $ 20 $ 10 0 + 10 + 20 + 30 + 40 + 50 + 60

5 23 41 59 77 95 113
∞F $4 14 32 50 69 86 104 122








































 




































































































































 


























































































































































 













 SAE 15 W > 30




































 



 



 



 



 



 



 



 



 



 



 



 



  



 



 



 



 



 



 



 



 



 



 




















































































































 







































 






















SAE 15 W > 40


























































































 
 

































 















































































































































































































SAE 10 W > 40














































































































 




























































































 






































































































































































































 




























































































  SAE 10 W > 30 














































































































































 































below $15 ∞C (5 ∞F), preheat the engine

26
3.00 LUBRICANTS AND SERVICE FLUIDS 021852>02

Engine oils

1. Oil change intervals

The first oil and filter change should be carried out between 50 and 100 operating hours. Subsequent filter
changes should occur every 500 operating hours, however, at least once a year.

Change the oil according to operating conditions and oil quality, in accordance with the chart shown on the
opposite page. However, the oil must be changed at least once a year.

It is not permitted to extend the oil change intervals by using partial flow filters!

For quantities, refer to the MOBILE CRANE operating manual.

2. Oil quality / specification

For modern Diesel engines, only highly alloyed lube oils are used today.
They consists of basic oils and additives.

The lube oil specifications for LIEBHERR Diesel engines is based on CCMC specifications, API classification
and / or US military specifications.

Depending on the engine type and the amount of load it is subjected to, certain minimum standards must be
met, some superior quality oils might permit an extension of oil change intervals.

If extended oil change intervals are desired, oil qualities above the CF>4 / CF / CE / D4 classification are
available, for example SHPD / D5.

3. Oil viscosity

In addition to oil specification, the oil must also conform to a certain viscosity which is determined by the
ambient temperature surrounding the engine. The selection is made according to SAE classifications (Society of
Automotive Engineers).

A viscosity which is too high can lead to starting difficulties, a viscosity which is too low can endanger the
efficiency of engine lubrication.

The temperature ranges shown in the chart on the opposite page are merely guidelines and operation above or
below these values is permitted for a short period only!

27
3.00 LUBRICANTS AND SERVICE FLUIDS 021852>02

∞C $ 40 $ 30 $20 $10

$31 $13 5 23
∞F $ 40 $22 $4 14 32

























































































































































































































































































35%



















































































































































Proportion


























in 






% 








































































































































 45%
 


 of 



 


 





 antifreeze 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 





























































































































































 
























































































































51%

28
3.00 LUBRICANTS AND SERVICE FLUIDS 021852>02

Coolant

Use only clean, soft water for the coolant mixture. Often, but no always, drinking water meets these
requirements. Sea water, brackish water, brine and industrial water water is not suitable.

To assure the corrosion protection of the coolant system, a year round mixture of at least 50% corrosion
preventative and antifreeze fluid and 50% water is specified, it assures freeze protection to approximately
minus 35 ∞C (>31 ∞F).

If temperatures fall below those temperature ranges, the corrosion / antifreeze ratio must be increased as shown
on the chart on the opposite page.

CAUTION: The percentage of corrosion preventative / antifreeze fluid should not exceed 60% , a
higher concentration will adversely affect freeze protection and heat transfer rates.

The chart on the opposite page shows the various mixture ratios.

If any antifreeze fluid has been lost and fluid is added, it must be ensured that the ratio of 50% is retained.

During regular maintenance, the ratio of the coolant mixture must be checked.
The coolant must be drained and replaced every 2 years.

Regarding corrosion preventatives / antifreeze fluids, only LIEBHERR approved corrosion preventatives and
antifreeze fluids may be used (refer to the MOBILE CRANE operating manual).

In exceptional cases, and if ambient temperatures constantly remain above freezing, such as in tropical regions,
where there is no corrosion preventative / antifreeze fluid available, the following mixture may be used as
coolant:
99% water and
1% additive (corrosion protective oil).

Mixing procedure for adding coolant:

First add water, then the corrosion preventative. The coolant additive should be premixed in a small container
and then added to the circulating coolant.
The fluid can also be mixed in commercially available mixing units.
For a first time mixture or when filling the coolant system after it has been drained or cleaned, an oil content of
1 to 1.5% has proven itself.
When using coolant refiners, always read and observe the manufacturerπs guidelines!
The concentration must be checked during regularly scheduled maintenance work, the oil content may not drop
below 1%.

IMPORTANT: When using coolant refiners, the coolant must be changed once a year.

When using coolant refiners, no glycol based antifreeze fluids or other antifreeze fluids may be used at the same
time.
Before changing from corrosion preventative / antifreeze fluid to coolant refiners, the total coolant and heating
circuit must first be flushed with water.

Coolant filling quantity: refer to MOBILE CRANE operating manual.

29
3.00 LUBRICANTS AND SERVICE FLUIDS 021852>02

30
3.00 LUBRICANTS AND SERVICE FLUIDS 021852>02

Diesel fuels

The Diesel fuel must meet the minimum specifications, as listed below. The sulfur content in the fuel must not
exceed!0.5%.
A higher sulfur content can affect oil change intervals and engine service life.

Permitted fuel specifications:

DIN EN 590
Nato Codes F 54, F 75
BS 2869 : A1 and A2
ASTM D 975 > 88 : 1 D and 2 D

CAUTION: DO NOT add fuel to the mobile crane if the engine is running. The engine must be
turned off before refueling!

Diesel fuels in cold climates:

When ambient temperatures are below 0 ∞C (32 ∞F), Diesel fuels normally used during the summer months may
suffer a decline in fluidity due to paraffin separation. The same occurs if Diesel fuels normally used during the
winter are used at temperatures below >12 ∞C (14 ∞F).
In order to prevent operating problems at these low temperatures, the Diesel fuel must be mixed with regular
gasoline or petroleum.
Mixing regular gasoline should be considered as a last resort, and under no circumstances should the ratio of
gasoline exceed 30%. Do not mix Super gasoline with regular gasoline.
Depending on the ratio of Diesel fuel to gasoline or petroleum, engine output may somewhat decline. For that
reason, taking the ambient temperature into account, keep the amount of regular gasoline you add to the Diesel
fuel as low as possible.
For safety reasons, mix the fuel only in the fuel tank. Add the specifically lighter regular fuel before adding the
Diesel fuel. Then run the engine long enough to run the fuel mixture throughout the total fuel system.

Mixing ratio

Ambient Summer Diesel fuel Normal fuel or Winter Diesel fuel Normal fuel or
temperature [∞C] [%] Petroleum [%] [%] Petroleum [%]

0 to >10 70 30 100 >

>10 to >15 50 50 100 >

>15 to >20 > > 70 30

>20 to >25 > > 50 50 *

* If an addition of 50% is necessary, use only petroleum (not regular gasoline)!

Other Diesel fuel additives (flow improvers):

Widely commercially available flow improvers also enhance Diesel fuel ability to perform reliably in cold
climate conditions.
When using such flow improvers, closely follow the manufacturerπs recommendations!

Fuel tank capacity: refer to MOBILE CRANE operating manual.

31
4.01 MAINTENANCE SCHEDULE 021146>04

32
4.01 MAINTENANCE SCHEDULE 021146>04

f f f
1 2 3 4 5 6 Maintenance work a b c d f f
f
x Oil level in engine x 1.
x Oil pressure x x
x Coolant temperature and battery charge indicator lamp x x
x Coolant level x 9.
x Air filter vacuum indicator x 10. x
x Liquid level of battery (at least once a week) x x
x Water separator at fuel step>filter x x 4.
x Fuel preliminary filter (or if engine power drops) x x 6.
x Dust collecting basin of air filter x 10.
x Engine governor and engine brake x 12.
x Radiator, pressure control valve, ventilator (visco fan) x x x 8.;13.
x Heater connection and coolant tubes x x x
1) x Engine oil (initially between 50 and 100 op. hours) * x 2.
1) x Lubricating oil filter (at first oil change), 2 ¥ x 3.
x Tension and state of V>belt (as required) x x x 11.
x Valve play x x x
x Fuel step>filter, 2 ¥ x 5.
x Dry air filter x 10.
x Grease toothed flywheel ring x x x
x Fixture of oil sump and engine support x x
x Fixture of suction tubes and tail>pipes x x
x Suction line between air filter and engine x x
x Flame starting device (at beginning of cold season) x x x
x Injection valve (or if performance drops) x x x x
x Thermostats x x x
x Compression x x
x Fuel delivery start x x x
x Coolant with corrosion preventive and antifreeze x 9.
x Oil separator x x

Intervals Jobs Notes

1 : daily a : check f see Chap. 4.02,

2 : every 100 hours b : clean point ...
3 : every 500 hours (min. once a year) c : renew f f see workshop manual
4 : additionally every 1000 hours d : adjust "LIEBHERR" > Engine
5 : additionally every 2000 hours f f f see operating manual
6 : additionally every 2 years MOBILE CRANE

1) First and only maintenance interval

* Pay attention to oil grade, see SERVICE FLUIDS chapter

33
4.02 MAINTENANCE WORK 021147>03

180125

180126

180127

180128

34
4.02 MAINTENANCE WORK 021147>03

1. Oil level check (Fig. 1)

> Engine must be in horizontal position when oil level is measured.
> Switch off engine, wait 2 to 3 minutes, pull out and wipe dipstick, then insert and remove once again.
> Add oil if necessary.
> The oil level must between the MIN. and MAX. marks on the dipstick.
> Under no circumstances should oil level be allowed to drop below the MIN. mark.

2. Oil change (Figs. 2 and 4)

> Change oil only when the engine is warm.
> Screw the supplied oil drain hose on to the waste oil plug and collect the oil in a suitable receptacle.
> Reclose the waste oil screw plug.
> Fill oil up to the upper marking on the dipstick (see point 1 for oil measurement procedure).
> For oil quality refer to chapter SERVICE FLUIDS
or MOBILE CRANE operating instructions chapter TABLE OF LUBRICANTS
For oil filling quantities, refer to chapter headed FILLING QUANTITIES in MOBILE CRANE operating
instructions.
> Start engine and check oil level (see MOBILE CRANE operating instructions).
CAUTION: Before starting the engine,turn the flywheel (2 to 3 times) by means of the motor
starter while engine stop is active.

3. Oil filter change (Fig. 3)

> Unscrew the lubricating oil filter cartridges.
> Clean the sealing surface of the filter console.
> Rub with oil the new filter cartridge and rubber sealing ring, and then firmly tighten with both hands.
Note: Only original LIEBHERR filter cartridges may be used.
> Start engine, check tightness and oil pressure.
CAUTION: Before starting the engine,turn the flywheel (2 to 3 times) by means of the motor
starter while engine stop is active.

35
4.02 MAINTENANCE WORK 021147>03

180129

180130

36
4.02 MAINTENANCE WORK 021147>03

4. Drain water separator (Fig. 5)

> Turn the water separator screws (1) and (2) to open.
> Drain off any water or condensation until clean fuel emerges, close the screws (1) and (2).
> Drain the water and / or fuel into an appropriate container and dispose of it properly.

CAUTION: Observe utmost cleanliness when performing any work on the fuel system!
Flush all fuel lines before use!

5. Change fuel filter (Fig. 5)

> Unscrew the fuel filter cartidges (3) and (4).
> Install new filter cartidges, and oil rubber sealing ring.
> Bleed fuel system.
Note: Only original LIEBHERR filter cartridges may be used.
> Filter (3) = 1st stage
> Filter (4) = 2nd stage

6. Change fuel preliminary filter (Fig. 6)

> Close shut>off valve (if fitted) at fuel tank.
> Slacken knurled nut (3).
> Swing out clamp clip and remove inspection glass (1) together with filter screen (2).
> Clean inspection glass and filter scren in clean diesel oil with a soft brush.

37
4.02 MAINTENANCE WORK 021147>03

180131

180132

180133

180134

38
4.02 MAINTENANCE WORK 021147>03

7. Bleed fuel system (Figs. 7/8/9 and 10)

> Slacken vent screw (1) at filter top and unscrew by 2 to 3 turns.
> Use the knurled grip to release hand primer (2) at the fuel delivery pump and operate primer until fuel
flows from the vent screw (1) without bubbles.
> Retighten vent screw (1).
> Unscrew fuel line (3) at the injector pump.
> Operate hand primer (2) until fuel emerges without bubbles. Tighten line (3) once again.
> Unscrew oil leakage return line with overflow valve (4).
> Operate hand primer (2) until fuel emerges without bubbles.
> Retighten overflow valve (4).
> Unscrew cap nut at the injection valves (5).
> Operate starter until fuel flows out without bubbles.
> Retighten cap nut (5).
> Start engine, and repeat bleeding procedure if necessary.

39
4.02 MAINTENANCE WORK 021147>03

180135

180136

180137

180138

40
4.02 MAINTENANCE WORK 021147>03

8. Water cooler and compensator reservoir (Figs. 11 and 12)

> Clean coolant pipe system at cooler if necessary.
> In the event of leakage, exchange the sealing cap (1) and pressure control valve at the compensator
reservoir.
CAUTION: Ensure that the coolant temperature is below 90∞C before opening the cooling
circuit sealing cap (1).
> Turn the sealing cap to the first locking position. Bleed excess pressure.
> Now turn further to the second locking position and remove sealing cap.

9. Coolant (Figs. 11/12/13 and 14)

Draining coolant
> Cooler: open drain screw (2).
> Engine: unscrew drain screw (3).
CAUTION: To drain the engine completely (for prolonged stillstand periods etc.), it is
necessary to drain the coolant from the coolant pump (4) also.

Filling coolant
> Close drain screws at cooler (2) and engine (3) and (4).
> Open heating valves.
> Pour coolant into compensator reservoir (1) (Fig. 11).
> Fill cooling circuit to maximum.
> Start engine and allow it to warm up.
> Now check the coolant level; refill if necessary.
> Filling quantity, refer to chapter headed FILLING QUANTITIES in Mobile Crane operating instructions.
CAUTION: To safeguard the corrosive prevention of the cooling circuit, the coolant must
contain approx. 45% corrosion preventive and antifreeze (see also FUELS
chapter).

41
4.02 MAINTENANCE WORK 021147>03

180139

180140

180141

42
4.02 MAINTENANCE WORK 021147>03

10. Dry air filter (Figs. 15/16 and 17)

Filter cartridge maintenance

We urgently advise that the filter cartridges be serviced only when signalled by the service indicator (Fig. 15) or
indicator lamp (Fig. 16). For this reason, clean or exchange the cartridges only if essential. However, cartridges
should be exchanged at least once a year, or if clogged with soot.

Note: Only original LIEBHERR filter elements may be used.

If the red "service field" remains fully visible in the mounted service indicator when the engine is not running,
or if the yellow air filter indicator lamp lights up when the engine is running, exchange or clean the filter
cartridge. The development of dense exhaust smoke or a deterioration in the engine output may indicate that
the air filter is clogged.

Dry cleaning

Blow compressed air through the filter element (3) contrary to the normal air flow direction, i.e. from the inside
out. The nozzle pressure (internal diameter below 3 mm) must not exceed 5 bar. Move the nozzle up and down
inside the element, keeping it a distance of at least 2 cm from the element casing. When dust emission is no
longer visible, cleaning can be stopped. Clean the filter housing and the inner sealing surface with a damp rag.
Do not blow out the housing.

CAUTION: The service life of the paper cartridges is dependent on timely emptying of the dust
receptacle (4). The excessive dust ratio caused by failure to empty the receptacle
results in rapid clogging of the cartridge. For this reason, the dust receptacle (4)
should never be allowed to become more than half>full. Daily emptying may be
required under certain circumstances.

Emptying the dust receptacle

> Switch off engine.

> Fold up clamp clip (6) and remove dust receptacle (4) together with the cap (5).

> After removing the cap (5), empty out the dust receptacle.

> Remount the receptacle in the reverse sequence; (grooves > see arrow > must interlock).

> If mounting filter in a horizontal position, ensure that the "TOP" marking is upmost.

43
4.02 MAINTENANCE WORK 021147>03

180142

180143

180144

180145

44
4.02 MAINTENANCE WORK 021147>03

11. V>belt (Figs. 18 and 19)

Changing V>belt
> Slacken screws (1/2/3) (Fig. 18).
> Slacken locking nut (4) and turn back adjusting screw (5).
> Swivel generator inwards as far as possible and remove V>belt.
> Mount new V>belt, adjust tension, and retighten all screws.

Checking V>belt tension manually

> If it is possible to press down the V>belt by approx. 10 mm at the central point (see arrow/Fig. 19) between
both pulleys, the V>belt tension has been adjusted correctly.

Checking tension with "Krikit" measuring instrument (Gates)

> Lower indicator arm (6) in measuring instrument (Fig. 20) and mount instrument on belt at central point
between the two pulleys.
> The side stop of the measuring instrument must be in contact with the side of the V>belt.
> Press pushbutton (7) with even pressure at right angle to V>belt until snap>in spring disengages.
> Carefully remove measuring instrument and read measured value at intersection point between the "KG"
scale and indicator arm (see arrow).
> Compare measured value with table below.

V>belt profile width New V>belt Run>in V>belt

[mm] KG scale KG scale

12,5 45 30 to 40

Adjustment
> Slacken screws (1/2/3) (Fig. 18).
> Slacken locking nut (4) and turn adjusting screw (5) until the correct V>belt tension is achieved.
> Tighten all screws.
> Now repeat V>belt tension test.

45
4.02 MAINTENANCE WORK 021147>03

180146

180147

180148

46
4.02 MAINTENANCE WORK 021147>03

12. Governor

Test control rod at injector pump (Figs. 21 and 22)

Check the control rod at the injector pump at full load, idle speed and stop position. When the accelerator is fully
depressed, the regulating lever (1) at the injector pump must be in full contact with the full load stop screw (2).
If a gap between regulating lever and stop screw remains, adjust rod. Apply a few drops of lubricating oil to
joints and bearing points.

Key to parts in Fig. 21

a > air regulating valve for motor regulation
b > solenoid valve for motor stop
c > control rod for throttle hand lever
d > air cylinder for speed reduction during crane operation (only featured in units with a diesel engine)

Test control rod at engine brake (Fig. 23)

Check smooth running of articulated joints of actuating cylinder (4). Lubricate joints. Operate brake flap (5).
After activation, the flap must return fully to the idle position.

This can be judged by the notch on the throttle valve shaft (see arrow/Fig. 23): the notch must be parallel with
the exhaust pipe.
Locking of the flap will result in engine overheating, increased fuel consumption and dense exhaust smoke.

47
4.02 MAINTENANCE WORK 021147>03

180149

180150

48
4.02 MAINTENANCE WORK 021147>03

13. Testing / blocking visco>fan (Figs. 24 and 25)

If the coolant temperature rises abnormally, first check whether coolant level is insufficient and whether the
radiator is clogged. If neither of the latter defects apply, it may be surmised that the visco>fan is not functioning
properly.

If the function of the visco>fan is impaired, check fan in accordance with following scheme:

The viscous oil flows back into the chamber if an engine is cold and not used for a longer period of time.
Therefore, when the engine is at a standstill, it should be difficult to rotate the fan manually.

Start the cold engine. Run up to medium speed for 1 or two minutes, then switch off. It should now be possible to
rotate the fan manually, since the silicone fluid which has been spun out is not able to flow back into the
chamber through the thermostats when the engine is cold.

The clutch can be blocked in event of a viscous clutch failure

The locking device (1) mounted at the rear of the fan can be used to rigidly connect the fan to the belt pulley.
To do so, turn the nut (2) anticlockwise (viewed from flywheel) by approx. 60∞ until it clearly catches. Now
rotate fan slowly by hand until the pin of the locking device clearly engages in position by means of the
internally>located pressure spring.

CAUTION: The visco>fan must always be transported and mounted in the vertical position.
Otherwise there is a risk of the silicone fluid running out.

49
4.03 CERTIFICATION OF COMPLETED MAINTENANCE WORK 021148>02

50
4.03 CERTIFICATION OF COMPLETED MAINTENANCE WORK 021148>02

Details on maintenance

Crane type: ...........................................

Crane no.: ...........................................

Engine type: ...........................................

Engine no.: ...........................................

Commissioned on: ...........................................

Customer: ...........................................

Town: ...........................................

Street: ...........................................

Liebherr Sales
and Service Office: ...........................................

Town: ...........................................

Street: ...........................................

Telephone/fax: ...........................................

Further notes:

Service and maintenance play an important role in determining whether an engine is fully operative at all
times and has a long service life.
We urgently recommend that the prescribed maintenance work be carried out carefully and in good time.
Failure to comply with these instructions will affect claims made under guarantee. The lead seals at the fuel>
injection pump and speed governor must never be removed!

Duly executed maintenance work must be entered and confirmed in the following maintenance chart.

Note: 1. Maintenance work specified as necessary on a daily or 100 operating hour basis must be
carried out by the customer's service personnel.
2. The first oil and oil filter change (after 50 to 100 operating hours) and all further upkeep
must be carried out by a contracted fitter who has been trained by Liebherr.

51
4.03 CERTIFICATION OF COMPLETED MAINTENANCE WORK 021148>02

every 500 hours / at least once a year

Operating
Date Fitter Signature Comment
hrs.

50 till 100 *

500

1 000

1 500

2 000

2 500

3 000

3 500

4 000

4 500

5 000

5 500

6 000

6 500

7 000

7 500

8 000

8 500

9 000

9 500

* only oil and filter change (first>time)

CAUTION: When running the engine under difficult operating conditions or if using low>grade
engine oils (see FUELS chapter), the specified oil and oil filter change interval must
be halved.

52
4.03 CERTIFICATION OF COMPLETED MAINTENANCE WORK 021148>02

every 500 hours / at least once a year

Operating
Date Fitter Signature Comment
hrs

10 000

10 500

11 000

11 500

12 000

12 500

13 000

13 500

14 000

14 500

15 000

15 500

16 000

16 500

17 000

17 500

18 000

18 500

19 000

20 000

CAUTION: When running the engine under difficult operating conditions or if using low>grade
engine oils (see FUELS chapter), the specified oil and oil filter change interval must
be halved.

53
4.03 CERTIFICATION OF COMPLETED MAINTENANCE WORK 021148>02

additionally every 1000 / 2000 operating hours

Operating
Date Fitter Signature Comment
hrs.

1 000

2 000

3 000

4 000

5 000

6 000

7 000

8 000

9 000

10 000

11 000

12 000

13 000

14 000

15 000

16 000

17 000

18 000

19 000

20 000

54
4.03 CERTIFICATION OF COMPLETED MAINTENANCE WORK 021148>02

additionally every 2 years

Operating
Date Fitter Signature Comment
hrs.

2 years

4 years

6 years

8 years

10 years

12 years

14 years

16 years

18 years

20 years

55
5.00 TROUBLESHOOTING 021149>01

Fault Cause Remedy

1) Engine
Fuel tank empty Fill fuel tank and deaerate fuel system
refuses to
start
Fuel preliminary filter clogged Clean filter

Fuel filter clogged, due to paraffin Replace fuel filter and deaerate fuel system
separation in winter Use winter fuel

Fuel lines leaking Check line connections for leaks and

tighten screw fittings

Starter defective Remove and have tested or repaired in

workshop

Battery run down Test and charge battery

Electrical connections at battery, starter or Check and tighten cable

ignition key loose

Flame starting device defective Check solenoid valve and flame glow plug.
(at low temperatures) Replace if necessary

2) Engine starts
All sources listed under point 1), except for see point 1)
briefly, then
electrical faults and flame starting device
stops
Aerator in fuel tank filler cap blocked Verschlu˚deckel reinigen

3) Engine runs
All sources listed under points 1) and 2), siehe Punkt 1) u. 2)
erratically,
except for electrical faults and flame
fails
starting device
periodically,
or power is
Air filter clogged Clean filler cap
reduced

Throttle valve for exhaust brake closed or Check throttle valve position
jammed

Overflow valve at fuel>injection pump Check and change if necessary

outlet does not maintain pressure

Valves in fuel supply pump leaking Have fuel supply pump tested in workshop,
and replace if necessary

Charge>air cooler clogged Clean charge>air cooler

56
5.00 TROUBLESHOOTING 021149>01

Fault Cause Remedy

3) Engine runs
Charge>air pressure too low Check exhaust>gas turbocharger
erratically,
fails
periodically,
Fuel>injection pump delivery start Check delivery start, and adjust if
or power is
misadjusted necessary
reduced
Injection nozzles catch or do not atomize Check, adjust or replace injection nozzles

Fuel>injection pump delivery quality Have fuel supply pump tested in workshop
misadjusted or control rod jammed

Throttle linkage not at full>load stop Check and adjust throttle linkage

Engine compression too low Check valves, piston and cylinders and
replace if necessary

4) Exhaust
Air filter clogged Clean air filter
emissions are
black
Leak in suction system Check / change hoses or lines

Throttle valve for exhaust brake closed or Check throttle valve position
jammed

Injection nozzles defective or carbon> Test, adjust or replace injection nozzles

encrusted

Fuel>injection pump delivery start Check delivery start, adjust if necessary

misadjusted

Fuel>injection pump delivery quantity Have fuel>injection pump tested in

excessive workshop

5) Exhaust
Rectify oil level
emissions are
Lubricating oil level in engine too high
blue
Lubricating oil penetrates combustion Overhaul or exchange cylinder heads,
chamber and is burned replace pistons and cylinder liners
Clearance between valve stem and guides
too large, piston rings worn, broken or
jammed, scuff traces on pistons and
cylinder liners

Compressor>sided seal at exhaust>gas Check exhaust>gas turbocharger, exchange

turbocharger defective if necessary

57
5.00 TROUBLESHOOTING 021149>01

Fault Cause Remedy

6) Exhaust
Cylinder head seal defective and cooling Renew cylinder head seal
emissions are
water penetrates combustion chamber
white
Injection nozzles leaky or do not atomize Renew cylinder head seal
completely

7) "Diesel
Fuel>injection pump delivery start Check, adjust injection nozzles, replace if
knock" in
misadjusted necessary
engine
Injection nozzles defective or carbon> Check delivery start, adjust if necessary
encrusted

8) Engine
Injection nozzles defective or carbon> Check, adjust and, if necessary, replace
knocks
encrusted injection nozzles

Piston rings worn or broken, pistons Check pistons and cylinder liners, change
scuffed if necessary

Main bearing or connecting rod bearing Renew or repair engine bearing

defective

9) Cooling water
Not enough water in cooling system Add cooling water
temperature
too high
Air in cooling system Deaerate cooling system

External dirt accumulation on radiator Clean radiator network

Radiator internally clogged or calcified Decalcify radiator

Thermostats defective Check thermostats, renew if necessary

Coolant pump defective Check coolant pump, repair or replace if

necesssary

Fan defective Check fan and replace if necessary

10) Lubricating
Oil level in oil sump too low Fill oil up to specified marking
oil pressure
too low
Lubricating oil viscosity too low Drain oil and fill prescribed grade

58
5.00 TROUBLESHOOTING 021149>01

Fault Cause Remedy

10) Lubricating
Oil pressure gauge or pressure transducer Check oil pressure and replace defective
oil pressure
defective transducer or gauge
too low
Lubricating oil pressure pump defective Replace lubricating oil pressure pump

Shutoff valve at lubricating oil pressure Check shutoff valve at lubricating oil
pump blocked in open state pressure pump and replace if necessary

Excessive bearing clearances due to wear Renew or repair engine bearing

or bearing damage

11) Lubricating
Oil cooler or cooler plate leaky Pinch off seal, replace if still leaky
oil in cooling
system
Cylinder head seals leaky Renew cylinder head seals

12) Cooling water

Cylinder head seals leaky Renew cylinder head seals
in lubricating
oil
O>rings at cylinder liners leaky Renew O>rings

59