Manual Del Operador Ingles

en Operator's manual
Diesel engine
LEC D9512 A7–00 / D9512 A7 Tier 2-
From serial number 2013160001
Document ID
Order number: 11429440
Issued: 01.12.2015
Version: 00
Author: LMB / Department ED5
Product ID
Manufacturer: LIEBHERR MACHINES BULLE S.A.
Type: LEC D9512 A7–00 / D9512 A7 Tier 2
Type no.:
From Serial no.: 2013160001
Contact
Address: LIEBHERR MACHINES BULLE S.A.
45, rue de l'Industrie
CH-1630 BULLE
SWITZERLAND
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 manufacture:
.............................
Commissioning date:
.................. / ................. / .................
LMB/11429440/00/01.12.2015/en
copyright © LIEBHERR MACHINES BULLE S.A. 01.1

LEC D9512 A7–00 / D9512 A7 Tier 2 /
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Foreword
These operating instructions have been compiled for the user and for the mainte-
nance personnel of the diesel engine.
The manual includes 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 malfunc-
tions resulting from improper use.
Please understand that we can 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 wherever spare parts other than original LIEBHERR spare parts or
spare parts purchased by LIEBHERR are used for maintenance or repair.
The maintenance intervals may be shorter than those prescribed in the inspection
plan when working in extreme conditions.
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 LIEB-
HERR 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.
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LEC D9512 A7–00 / D9512 A7 Tier 2 /
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Foreword Operator's manual
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LEC D9512 A7–00 / D9512 A7 Tier 2 /
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Contents
1 Product Description 9
1.1 Technical description 9
1.1.1 Overview of assembly 9
1.1.2 Explanation of type description 12
1.1.3 Design features 15
1.1.4 Special equipment for the diesel engine 17
1.2 Technical data 18
1.2.1 Diesel engine 18
1.2.2 Cylinder head, standard 18
1.2.3 Coolant pump 18
1.2.4 Coolant thermostat 19
1.2.5 Generator 19
1.2.6 Starter 19
1.2.7 Flywheel housing 19
2 Notes on safety 21
2.1.1 Designation of warning information 21
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 Observing the safety precautions upon start-up 23
2.7 Measures for safe maintenance 24
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2.8 Observe the safety precautions for diesel engines featuring electronic control
units 25
2.9 Safety and emergency run program for diesel engines featuring electronic
control units 26
2.10 Special notes regarding tasks on the Common Rail System 26
2.11 Disposal of operating fluids 28
3 Operation, servicing 29

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Contents Operator's manual
3.1 Control and operating elements 29

3.2 Operation 30
3.2.1 Preparations prior to initial start-up 30
3.2.2 Initial start-up / test run 30
3.2.3 Starting the diesel engine. 31
3.2.4 Starting in frosty temperatures 32
3.2.5 Switching off the diesel engine. 32
4 Malfunctions 35
4.1 Faults - Cause - Remedy 35
5 Maintenance 41
5.1 Maintenance and inspection chart 41
5.2 Fill quantities 44
5.3 Lubricants and operating fluids 45
5.3.1 Diesel fuels 45
5.3.2 Lubricating oil 45
5.3.3 Coolant 46
5.4 Special tools for maintenance tasks 47
5.5 Preparatory maintenance tasks 49
5.6 Daily maintenance tasks (every 10 operating hours) 50
5.6.1 Checking the engine oil level 50
5.6.2 Visual inspection (leaks, contamination, damage) 50
5.6.3 Checking the coolant level 51
5.6.4 Checking / draining the water separator of the fuel prefilter (variant 1) 51
5.6.5 Checking / draining the water separator of the fuel prefilter (variant 2) 54
5.6.6 Checking low-pressure display of the air filter 54
5.7 Weekly maintenance tasks (every 50 operating hours) 55
5.7.1 Draining water and sediment in the fuel tank 55
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5.7.2 Cleaning the dust-discharge valve of the air filter 55

5.8 Maintenance Tasks, every 250 operating hours 56
5.8.1 Replacing the fuel prefilter element 56
5.8.2 Replacing the fuel fine-filter 57
5.9 Maintenance Tasks, every 500 operating hours 58
5.9.1 Checking condition of the belt drive and replacing as necessary. 58

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Operator's manual Contents
5.9.2 Checking the induction and exhaust gas system for sound condition
and for leaks 60
5.9.3 Checking the cooling and heating systems for sound condition and for
leaks 60
5.9.4 Checking the lubrication system and fuel system for leaks and for
sound condition 60
5.9.5 Replacing the fuel prefilter element (Variant 1) 61
5.9.6 Replacing the fuel prefilter element (Variant 2) 63
5.9.7 Replacing the fuel fine-filter 63
5.9.8 Replacing the fuel fine-filter for remote mounted fuel fine-filter 65
5.9.9 Checking batteries and cable connections 66
5.9.10 Checking the control unit mounting for sound condition 66
5.9.11 Checking sensors, actuators, cable fittings and plugs for sound
condition 66
5.10 Maintenance tasks every 1000 operating hours 67
5.10.1 Changing diesel engine oil and replacing the oil filter element 67
5.10.2 Replacing the crankcase breather oil separator filter element. 70
5.10.3 Checking the oil sump, engine mount and diesel engine brackets for
secure seating 72
5.11.1 Replacing the ribbed V-belt and tensioning device 73
5.11.2 Checking and adjusting valve clearance 74
5.11.3 Checking correcting anticorrosive and antifreeze concentrations in the
coolant 82
5.12.1 Crankcase aeration 84
5.12.2 Replacing the fuel high-pressure pump 85
5.12.3 Injection nozzle / cylinder head cover seal 86
5.12.4 Replacing the fuel injection lines 87
5.12.5 Replacing the water pump 88
5.12.6 Replacing the coolant 88
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5.13.1 Replacing the Visco-damper (vibration damper) 91
5.14 Maintenance tasks as required 92
5.14.1 Checking the heater flange 92
5.14.2 Bleeding the fuel system 92
5.14.3 Extracting a sample of engine oil 94

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Contents Operator's manual
5.14.4 Replacing the dry air filter main element 95

5.14.5 Replacing the dry air filter safety element 95
5.15 Transport and storage 96
5.15.1 Lifting gear 96
5.15.2 Storage up to 6 months 97
5.15.3 Storage for between 6 and 24 months 97
Index 99
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1 Product Description
1.1 Technical description
1.1.1 Overview of assembly

This section features a summary of the diesel engine including a description of the
components represented.
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Fig. 1: Components of the diesel engine / as viewed from the left-hand side
1 Air-conditioning compressor 6 Heater flange 11 Oil sampling point
2 Crankshaft 7 Lifting eye 12 Engine oil filter element
3 Coolant manifold 8 Charge air connection 13 Starter
4 Coolant pump 9 High-pressure pump 14 Oil dipstick
5 Alternator 10 Oil intake

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Product Description Operator's manual
Technical description
Fig. 2: Components of the diesel engine / as viewed from the right-hand side
1 Flywheel 6 Engine oil filter element 11 Oil sump
2 Flywheel housing 7 Engine control unit 12 Starter
3 Exhaust turbocharger 8 Crankcase aeration 13 Engine bracket
4 Air intake 9 Lifting eye
5 Fuel fine filter 10 Alternator
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Operator's manual Product Description
Fig. 3: Components of the diesel engine / as viewed from the left-hand side
1 Air-conditioning compressor 6 Heater flange 11 Oil sampling point
2 Crankshaft 7 Lifting eye 12 Engine oil filter element
3 Coolant manifold 8 Charge air connection 13 Starter
4 Coolant pump 9 High-pressure pump 14 Oil dipstick
5 Alternator 10 Oil intake
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LEC D9512 A7–00 / D9512 A7 Tier 2 /
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Fig. 4: Components of the diesel engine / as viewed from the right-hand side
1 Flywheel 5 Engine oil filter element 9 Alternator
2 Flywheel housing 6 Engine control unit 10 Oil sump
3 Exhaust turbocharger 7 Crankcase aeration 11 Starter
4 Air intake 8 Lifting eye 12 Engine bracket
1.1.2 Explanation of type description
Engine classification
Description
D 95 12 A7 –00 Engine type description
D Engine type: D = Diesel engine
95 Bore: 128 mm / Stroke: 157 mm
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12 Number of cylinders: 12 = 12 cylinders

A7 Injection system: A7 = Common Rail
–00 Without emission type approval
Tab. 1: Engine classification

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Diesel engine identification plate

The diesel engine identification plate is mounted on the left-hand side of the crank-
case as viewed towards the flywheel.
Fig. 5: Identification plate
Diesel engine number

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Fig. 6: Diesel engine number

1 Year 3 Serial number
2 Number of cylinders (16=12-
cylinder)

LEC D9512 A7–00 / D9512 A7 Tier 2 /
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Engine control unit identification plate
Fig. 7: Example of identification plate for an engine control unit

1 Date of delivery 6 Engine serial number
2 2D code bar 7 Control unit identification number
3 Engine type 8 Update index
4 Control unit designation 9 Software version
5 Engine identification number 10 Control unit serial number
Note The information on the engine control unit identifi-

cation 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 diagnostic and service tool,
Sculi.
Tab. 2
Cylinder designation, rotational direction LMB/11429440/00/01.12.2015/en
Fig. 9: Cylinder designation / rotational direction
Cylinder 1 is located on the opposite side of the flywheel on the right. The rota-
tional direction is to the left, as viewed towards the flywheel.

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1.1.3 Design features
Design
Water-cooled 12-cylinder V-diesel engine with CR (Common Rail) direct injection,
exhaust turbocharging and air to air intercooling.
Features
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 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.
Drive mechanism
The 12-cylinder V-diesel engine features a forged steel crankshaft with 9 bearing
points, with inductive hardened running surfaces and counterweights. A torsion
damper is mounted on the crankshaft on the same side as the fan. Precisely
forged, 'cracked' connecting rods, transmission bearing in lead-bronze, triplex-fric-
tion bearings or sputter bearing. Steel Monotherm pistons featuring strut support
and cooling duct. Replaceable, wet cylinder liners.
Housing
Rigid, crankcase upper section lowered on one side with noise-optimised, vermic-
ular cast iron structure and a bedplate of duct cast iron as crankcase lower section.
Four-valve individual cylinder heads one charging port and one 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 by steel camshaft with 7 bearings via roller tappet, push
rod and rocker arm. Drive comprised of:
– Cam shaft
– High-pressure pump
– Fuel delivery pump
– Auxiliary hydraulic pump
from the crankshaft via case-hardened gear wheels on the flywheel side; Coolant
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pump and two lube oil pumps on the same side as the aggregate carrier.
Lubrication
Forced-fed lubrication with lube oil pumps for crankshaft bearing, connecting rod
bearing and camshaft bearing, as well as small end bush, roller tappet and rocker
arm. Oil filtering via two filter modules featuring integrated oil cooler and crankcase
breather in the main flow. Accessories, including high-pressure pump, coolant
pump drive, turbocharger and power take-off are connected to the diesel engine
lube oil circuit.

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Engine oil sampling point

The new D9512 features an engine oil sampling point 1.
Fig. 10: Oil sampling point

1 Oil sampling point 2 Sealing cap
Oil quality is to be guaranteed by way of regular oil analyses. An oil sample can be
extracted from the oil sampling point for this purpose. For further information, refer
to the chapter “Maintenance”.
Cooling
Thermostat-controlled 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.
Injection system
High-pressure pump, supplied from a flange-mounted fuel transfer pump. Fuel
filter; rail; CR-injectors with multi-jet blind hole nozzles.
Electronic diesel engine regulation

The electronic diesel engine controller (EDC) serves to regulate the speed, injec-
tion begin and torque of LIEBHERR diesel engines. The EDC comprises essen-
tially of sensors, the injection system and both engine control units (Master /
Slave). 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.
Electronic sensors on the engine side

Boost pressure sensor, fuel pressure sensor, rail pressure sensors, oil pressure
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sensor, temperature sensor for refrigerant, charge air and speed sensors are inter-
faces 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 power take-offs.

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1.1.4 Special equipment for 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. The magnetic clutch
is active when the air-conditioning system is switched on. The compressor is func-
tioning.
Cold start package

The interfaces for the retrofitting of pre-heating devices, for example for coolant,
fuel and diesel engine oil are already integrated.
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Technical data
1.2 Technical data
1.2.1 Diesel engine
Description Unit Value

Design V-diesel engine
Number of cylinders 12
Firing sequence 1–12–2–11–3–10–
6–7–5–8–4–9
Bore mm 128
Stroke mm 157
Displacement l 24,24
Compression ratio 21:1
Rotational direction of the diesel engine (as left
viewed towards the flywheel)
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
Weight of diesel engine without oil, without kg 2200
water
1.2.2 Cylinder head, standard

Valve clearance intake cold see identification
plate
Valve clearance exhaust cold see identification
plate
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1.2.3 Coolant pump

Flow rate (at nominal speed 1800 rpm and l/min 950
counterpressure 0.6 bar)

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Technical data
1.2.4 Coolant thermostat

Beginning of opening °C 82
Fully opened °C 92
1.2.5 Generator

Voltage V 28
Amperage A 140
1.2.6 Starter

Voltage V 24
Output kW 8.4
1.2.7 Flywheel housing

Connection SAE 0
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Technical data
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2 Notes on safety
Working on the diesel engine is extremely hazardous to the user, machine operator
or maintenance technician. Hazardous situations 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 guar-
antee 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
manual.
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
The warning sign is always displayed in correlation with the signal words:
DANGER
WARNING
ATTENTION
DANGER Signifies an imminent hazardous situation which

will result in fatalities or serious physical injury if it
is not prevented.
WARNING Signifies a dangerous situation which can result
in fatalities or serious physical injury if it is not
prevented.
ATTENTION Signifies a dangerous situation which can result
in minor or moderate injury if it is not prevented.
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CAUTION Signifies a dangerous situation which can result

in material damage if it is not prevented.
Tab. 4

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Notes on safety Operator's manual
Use as directed
Further designations
Note Signifies useful notes and tips.
Tab. 5
Additional rules and regulations

Observation of these points does not exempt you from adherence to the
additional rules and regulations!
2.2 General notes on safety
1. 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.
2. Only expressly authorised personnel may perform operation, maintenance or
repair of the machine.
Observe the legal, permissible minimum age!
3. Employ only trained or instructed personnel and allocate definitive responsi-
bility for personnel regarding operation, setting up, maintenance and repair.
4. Personnel who are still undergoing training, or who are involved with a general
apprenticeship should only be allowed to work on the diesel engine while
under constant supervision of an experienced person.
5. Ensure regularly that personnel are conscientious of safety and hazardous
situations while working, and are observing the operating instructions.
6. 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.
2.3 Use as directed
1. 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
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not be held responsible for any damage which occurs as a result. The user
bears full responsibility.
2. 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.
3. 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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Operator's manual Notes on safety
Observing the safety precautions upon start-up
2.4 Notes on the prevention of crushing and

burns
1. Do not use any lifting materials, such as ropes or chains, which are damaged
or do not feature sufficient lifting capacity.
Always wear industrial gloves when handling wire cables.
2. 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.
3. When verging on operating temperature, the diesel engine's cooling system is
hot and pressurised.
Avoid any contact with parts carrying cooling water.
Risk of burns!
4. 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.
5. The diesel engine oil is extremely hot when verging on operating temperature.
Avoid skin contact with hot oil or parts carrying oil.
6. 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 explo-

sions
1. The diesel engine must be switched off when refuelling.

Switch off any other additionally installed heating.
2. Do not smoke and avoid naked flames in the area where batteries are being
recharged and when refuelling.
3. Always start up the diesel engine in accordance with the guidelines stipulated
in the operating instructions.
4. Check the electrical system.
Remedy all faults, such as loose connections and worn cables immediately.
5. Check all lines, hoses and threaded unions regularly for leaks and damage.
6. Remedy leaks and replace damaged components immediately.
2.6 Observing the safety precautions upon

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start-up
1. Unless otherwise specified, always start up the diesel engine in accordance

with the guidelines stipulated in the operating instructions.
2. Start the diesel engine and then check all display equipment and control
devices.
3. Only allow the diesel engine to run in enclosed areas if sufficient ventilation
has been provided.

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Measures for safe maintenance
If necessary, open doors and windows to guarantee a sufficient supply of fresh

air.
2.7 Measures for safe maintenance
1. Do not carry out any maintenance or repair tasks with which you are not
familiar.
2. 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 equip-
ment appropriate for the respective task is used.
3. 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 oper-
ating and maintenance instructions may be performed by the machine oper-
ator or the maintenance personnel. All other tasks may only be carried out by
authorised personnel who have undergone the appropriate training.
4. Spare parts must comply with the technical requirements specified by the
manufacturer. This can always be guaranteed with original spare parts.
5. Always wear protective clothing when carrying out maintenance tasks.
6. Unless otherwise specified in these operating instructions, all maintenance
tasks for the diesel engine must be carried out on firm, level ground with the
diesel engine switched off.
7. When carrying out maintenance and repair tasks, tighten the loosened screw
connections with the prescribed tightening torque.
8. 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.
9. 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 breather, electronics box, starter and generator are at partic-
ular risk.
Additional tasks:
• After cleaning, remove the covers or adhesive bondings completely.
• After cleaning, examine all fuel lines, diesel engine oil lines and engine oil
lines for leaks, loose connections, points of wear and damage.
• Remedy any ascertained faults immediately.
10. Observe the safety guidelines valid for the respective product when handling
oils, greases and other chemical substances.
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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 pres-
surised, 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.

LEC D9512 A7–00 / D9512 A7 Tier 2 /
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Observe the safety precautions for diesel engines featuring electronic
control units
16. Do not try to lift heavy parts. Suitable lifting gear featuring sufficient lifting
capacity must be used for these tasks.
Procedure:
• Tighten and secure individual parts and larger assemblies carefully to the
lifting gears when replacing heavy parts to eliminate any hazardous situa-
tions.
• Only use suitable and technically sound lifting gear, as well as load carrying
equipment featuring sufficient lifting capacity.
It is prohibited to remain or work beneath suspended loads.
17. Do not use ropes which are damaged, or do not feature sufficient lifting
capacity. Always wear industrial gloves when handling wire cables.
18. Tasks on electrical equipment around 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. Additionally,
remove the plug from the control unit when performing electrical welding work
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
1. Only start up the diesel engine with the batteries securely connected.
2. Do not disconnect batteries while the diesel engine is running.
3. The diesel engine may only ever be started with the control unit connected.
4. 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 electrical welding tasks, the batteries must be disconnected
and both cables (positive and negative) must be securely connected with each
other. Connection to the engine electronics is to be disconnected via the inter-
face plugs.
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 incor-
rect polarity of the batteries) can lead to ruination of the control units.
9. Tighten the connections on the injection system with the prescribed tightening
torque.
10. If temperatures exceeding 80 °C are anticipated (e.g. drying ovens), the
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control unit 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.

LEC D9512 A7–00 / D9512 A7 Tier 2 /
2013160001 25
Special notes regarding tasks on the Common Rail System
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.
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).
If a fault is detected, one of the following measures is automatically initiated
following evaluation of the fault:
• Issue of an error report featuring error code.
• The error code is issued directly via a display in conjunction with the
vehicle diagnostics system.
• Changeover to suitable back-up function for further, however, limited oper-
ation of the diesel engine (e.g. constant emergency-run speed).
Have all faults remedied immediately by the respective Lieb-
herr After Sales Service.
2.10 Special notes regarding tasks on the

Common Rail System
1. With the diesel engine running, the lines are under a constant fuel pressure of
up to 2000 bar.
• Never loosen the screw connections on the fuel high-pressure side of the
Common Rail System (injection from the high-pressure pump to the rail, at
the rail and on the cylinder head to the injector) while the diesel engine is
running.
2. Any fuel which escapes while pressurised 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 fitted may not approach any nearer than 20 cm
to the diesel engine while it is running.
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• Do not touch voltage-carrying parts on the electrical connection of the injec-

tors while the diesel engine is running.
3. 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 high-
precision technology, utmost cleanliness must be guaranteed whenever tasks
on the fuel system are undertaken.
Dirt particles exceeding 0.2 mm are already large enough to cause failure of
components.

LEC D9512 A7–00 / D9512 A7 Tier 2 /
26 2013160001
Special notes regarding tasks on the Common Rail System
4. It is absolutely imperative, therefore, that the following prescribed measures

are adhered to before commencing any tasks:
• Before commencing any tasks on the clean side of the fuel system, the
diesel engine and the diesel engine compartment must be cleaned (steam-
jet cleaning), ensure that the fuel system is closed.
• Carry out a visual inspection of the fuel system for leaks or damage.
• Do not spray directly onto electrical components with the steam jet cleaner,
mount covers wherever necessary.
• 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 air disturbances (possible raising of dust by starting the diesel
engines, aeration or heating of the workshop or 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, clean cover sheet over areas of the diesel engine compart-
ment which may be prone to releasing dirt particles.
• Before commencing the disassembly work, wash your hands and put on
clean overalls.
5. 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 clean 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 care-
fully 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 the components.
• New parts may only be removed from their original packaging immediately
before use.
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• 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.

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Disposal of operating fluids
2.11 Disposal of operating fluids
Concerning scrap materials and hazardous waste, such as for example:

– Oils, lubricant, refrigerant from air conditioning systems etc.
– Coolant
– Fuels
– Filters, oil filter cartridges etc.
DANGER
Inadvertent filling of operating fluids in food or beverage containers
Operating fluids could be drunk accidentally.
Danger to health and life.
u Do not use food or beverage containers to drain operating fluids!
u Use leak-proof containers to drain operating fluids!
Note
Danger to environment and health
u Observe the country-specific regulations regarding environmental protection
when disposing of used consumables.
u Before disposing or recycling waste products, ask for the correct method at the
responsible environmental or recycling centre.
u Different operating fluids are to be collected and disposed in separate
containers.
u Make sure that no operating fluids end up in the soil, sewer system or water.
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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.
Data pertaining to oil pressure, coolant temperature, speed, operating hours and
service code, for example, are transferred to the machine via the electronic inter-
face on the diesel engine for operation and regulation of the diesel engine.
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LEC D9512 A7–00 / D9512 A7 Tier 2 /
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Operation, servicing Operator's manual
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, refer to the chapter “Filling amounts”.
For quality, refer to 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, refer to the chapter “Fuel and lubri-
cants”.
– Coolant
For coolant composition, refer to the chapter “Fuel and lubricants”.
– Diesel fuel
Use summer fuel or winter fuel in accordance with the respective season.
Diesel fuels must comply with the permissible fuel specifications, refer to the
chapter “Fuel and lubricants”.
WARNING
Naked flames!
Risk of 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, refer to the chapter “Mainte-
nance”).
3.2.2 Initial start-up / test run

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

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Operator's manual Operation, servicing
Operation
Troubleshooting
No oil pressure has been attained within 5 seconds?
u Switch off diesel engine immediately.
u Ascertain 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, refer to the chapter “Mainte-
nance”).
u Check the diesel engine oil level (for correct procedure, refer to the chapter
“Maintenance”).
u Inspect the diesel engine for leaks (for correct procedure, refer to the chapter
“Maintenance”).
3.2.3 Starting the diesel engine.

Ensure that sufficient fuel has been filled.
u Start the diesel engine in the idle position 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:
LMB/11429440/00/01.12.2015/en
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.

LEC D9512 A7–00 / D9512 A7 Tier 2 /
2013160001 31
Operation
NOTICE
u Run the diesel engine warm.

w Coolant temperature > 60 °C
3.2.4 Starting in frosty temperatures
Fig. 16: 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 (refer to the chapter Fuel and lubri-
cants under Diesel fuels at lower temperatures).
– Preheat the induction air (refer to the documentation of the machine manufac-
turer).
WARNING
Utilisation of ether-based starting aids!
Risk of explosion.
u Do not use ether-based starting aids.
NOTICE
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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.

LEC D9512 A7–00 / D9512 A7 Tier 2 /
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Operator's manual 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.
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Operation
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34 2013160001
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. 6
Fundamental logical steps for diagnosis are included in the following list:
– Familiarity with the diesel engine and all associated systems.
– Scrutinise the problem meticulously.
– Correlate the symptoms and knowledge of the diesel engine and its systems.
– Diagnose the problem, whereby the simplest assumptions are considered.
– Double check before beginning disassembly.
– Establish the causes and perform repair work thoroughly.
– Following repair, allow the diesel engine to run under normal operating condi-
tions and check whether the problem and the cause have been remedied.
4.1 Faults - Cause - Remedy
Malfunction / error Cause Remedy

Starter will not crank Main fuse is burned out Replace the fuse.
Battery connections loose or Clean and tighten loose connections
corroded
Battery voltage too low Recharge or replace battery
Starter electric circuit interrupted or Consult Lieb-
contacts corroded herr After Sales Service.
Starter faulty Consult Lieb-
LMB/11429440/00/01.12.2015/en

Starter will crank only slowly Battery voltage too low Recharge or replace battery
Battery connections loose or Clean and tighten loose connections
corroded
Ambient temperature too low Observe the measures for winter
operation.

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Malfunctions Operator's manual
Faults - Cause - Remedy

Diesel engine will not start or cuts Fuel tank is empty Refuel, bleed the fuel system.
out again shortly afterwards.
Fuel filter clogged Replace the fuel filter.
Fuel line, pre-cleaner or sieve in fuel Clean and bleed the fuel system.
tank is clogged
Fuel system or filter leaking 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 (with cold Inspect the heater flange and
temperatures) replace as necessary.
Diesel engine has difficulty starting. Leakages or insufficient pressure in Inspect for leaks (visual inspection);
the fuel low-pressure circuit to be carried out by Liebherr after-
sales services
Diesel engine - insufficient compres- Consult Lieb-
sion herr After Sales Service.
Fault in the electronics Read out error memory from engine
control unit, consult Lieb-
Diesel engine shuts down without Voltage supply cuts out Consult Lieb-
warning. herr After Sales Service.
Leakages or insufficient pressure in Inspection for leaks (visual inspec-
the fuel low-pressure circuit tion); to be carried out by Liebherr
after-sales services
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Operator's manual Malfunctions

Poor diesel engine output (output Fuel system faulty (clogged, leaking) Visual inspection for leaks, replace
deficiency) filter, consult Lieb-
Boost pressure too low Loose clamps, faulty seals and
hoses, air filter contaminated, turbo-
charger has no output.
Charge air temperature too high Intercooler contaminated, poor fan
(automatic reduction in output by output, ambient temperature too
engine control unit) high, consult Lieb-
Coolant temperature too high (auto- Check cooler for contamination,
matic reduction in output by engine check fan and thermostat, check
control unit) coolant level, consult Lieb-
Coolant temperature too high (auto- Consult Lieb-
matic reduction in output by engine herr After Sales Service.
control unit)
Application area more than 1800 M No remedy, diesel engine output
above sea level was reduced automatically.
Injection nozzles getting stuck or not Consult Lieb-
spraying. herr After Sales Service.
Diesel engine - insufficient compres- Consult Lieb-
sion herr After Sales Service.
Poor diesel engine braking action Diesel engine brake flap not func- Functional check and visual inspec-
tioning tion; Consult Lieb-
Fault in the electronics Consult Lieb-
Diesel engine is becoming too hot Insufficient coolant Refill
(indicated on the coolant tempera-
Cooler interior contaminated or calci- Clean or decalcify.
ture display)
fied, cooler exterior heavily contami-
nated
Thermostat faulty Check and replace as necessary,
consult Liebherr After Sales Service.
Coolant temperature sensor faulty Check and replace as necessary,
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consult Liebherr After Sales Service.

Speed of fan too low (hydrostatic fan Check fan drive and replace as
drive only) necessary, consult Liebherr Lieb-

LEC D9512 A7–00 / D9512 A7 Tier 2 /
2013160001 37

Charging current indicator lamp Insufficient tension in ribbed V-belt Check belt tension, if necessary
lights up when the diesel engine is replace tension pulley
running
Ribbed V-belt torn Replace ribbed V-belt.
Cable connections loose or discon- Secure or replace cable.
nected
Alternator, rectifier or governor faulty Consult Lieb-
Diesel engine emitting black smoke. Injection nozzles getting stuck or not Consult Lieb-
spraying. herr After Sales Service.
Turbocharger faulty (boost pressure Consult Lieb-
insufficient) herr After Sales Service.
Exhaust gases are blue in colour. Oil level in diesel engine too high Adjust oil level correctly.
Lube oil is entering the combustion Consult Lieb-
chamber and is being burned. herr After Sales Service.
Seals on the compressor side on the Consult Lieb-
exhaust turbocharger faulty herr After Sales Service.
Crankcase breather faulty Check and replace as necessary.
Exhaust gases are white in colour. Injection begin too late Consult Lieb-
Diesel engine knocking. Irregular combustion Consult Lieb-
Diesel engine rattling. Valve clearance too great Adjust valve clearance
Injection nozzles faulty or carbon- Consult Lieb-
ised herr After Sales Service.
Damaged bearings Consult Lieb-
Piston rings worn or broken, piston Consult Lieb-
corroded herr After Sales Service.
Irregular noises Leakages at the induction pipe and Remedy leakages, if necessary
exhaust gas pipe cause whistling replace seal.
noises.
Rubbing of turbine wheel or Consult Lieb-
compressor impeller on the housing; herr After Sales Service.
Foreign bodies in compactor or
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turbine; Seized bearing of rotating

parts

LEC D9512 A7–00 / D9512 A7 Tier 2 /
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Operator's manual Malfunctions

Insufficient lube oil pressure Oil level in the oil sump too low Fill in oil up to the prescribed
marking.
Viscosity of lube oil too low (thinning Drain oil, fill in prescribed oil.
of oil by diesel fuel)
Pressure sensor faulty Check oil pressure and replace
faulty oil pressure sensor; Consult
Liebherr After Sales Service.
Final check valve not functioning Consult Lieb-
correctly or dirt in final check valve. herr After Sales Service.
Bearing clearance too great due to Consult Lieb-
wear or bearing damaged herr After Sales Service.
Lube oil in the cooling system Oil cooler or oil cooler grill leaking Consult Lieb-
Cooling water in the lube oil O-rings on the cylinder liners not Consult Lieb-
tight herr After Sales Service.
Oil cooler or oil cooler grill leaking Consult Lieb-
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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:
The maintenance and inspection tasks must be performed or supervised here by
Liebherr specialist personnel or their authorised dealers. The maintenance inter-
vals apply as follows: Upon commissioning and then every 500, 1000, 2000 oper-
ating hours (h) and special intervals.
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LEC D9512 A7–00 / D9512 A7 Tier 2 /
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Maintenance Operator's manual
Maintenance and inspection chart
Customer:.......................... Machine type:.....................................Serial no.:...................Operating hours:.....................Date:.................................
Maintenance / inspection after service Tasks to be performed

hours
By maintenance staff By authorised specialist staff

On handover
All 8-10 h
All 50 h
All 500 h
All 1000 h
All 2000 h
All 3000 h
Other intervals n Once-only activity o Once-only activity
l Repeat interval m Repeat interval
ª If necessary ² If necessary
T Annually before the winter
Diesel engine
l l m m m m Check the engine oil level.
l l m m m m Visual inspection (leaks, contamination, damage)
m m m Change diesel engine oil (however, at least once a year): Applicable
for Liebherr engine oil. Other oil qualities and difficulty factors see
chapter 5.3.2. Lubricating oil.
m m m Replace the oil filter element (however, at least once a year)
m m m Replace the crankcase breather oil separator filter element.
m m m m Check condition of the belt drive and replace as necessary.
m Replace ribbed V-belt and tensioning device.
o m m m Check induction and exhaust systems for sound condition, secure
fastening and leaks.
m m m Ensure secure fastening of oil sump, engine mounting and diesel
engine brackets.
T Check the heater flange.
m15000h Replace the Visco-damper.
Cylinder head - valves
m Check / adjust valve clearance
Cooling system
l l m m m m Check the coolant level
m m m m Check the cooling and heating systems for sound condition and for
leaks.
m T Check anticorrosive and antifreeze concentrations in the coolant.
m7500h Replace the coolant.
Fuel system
l l m m m m Check water separator on the fuel prefilter 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 condi-
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tion.
m m m m Replace the fuel prefilter (or with output deficiency)
m m m m Replace the fuel fine-filter.
² Bleed the fuel system (injection lines may not be loosened)
Fuel system in application in Indonesia (or countries with similar fuel quality)
l l m m m m Check water separator on the fuel prefilter and drain water as
required.
l m m m m Drain water and sediment in the fuel tank.

LEC D9512 A7–00 / D9512 A7 Tier 2 /
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Operator's manual Maintenance
Maintenance and inspection chart
Customer:.......................... Machine type:.....................................Serial no.:...................Operating hours:.....................Date:.................................
Maintenance / inspection after service Tasks to be performed

hours
By maintenance staff By authorised specialist staff

On handover
All 8-10 h
All 50 h
All 500 h
All 1000 h
All 2000 h
All 3000 h
Other intervals
n Once-only activity o Once-only activity
l Repeat interval m Repeat interval
ª If necessary ² If necessary
T Annually before the winter
m m m m Check lube oil system and fuel system for leaks and for sound condi-
tion.
m m m m m250h Replace the fuel prefilter (or with output deficiency)
m m m m m250h Replace the fuel fine-filter.
² Bleed the fuel system (injection lines may not be loosened)
Air filter
l l m m m m Check low-pressure display for the air filter.
l m m m m Clean 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 Check batteries and cable connections.
o m m m Check control unit mounting for sound condition.
o m m m Ensure sound condition of sensors, actuators, cable fittings and plugs.
Midlife
m7500h Midlife kit
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Fill quantities
5.2 Fill quantities
Description Quantity
Engine oil 99 l (1.5 l per filter)
Coolant 65 l
Tab. 7: Fill quantities of lubricants and operating fluids
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Lubricants and operating fluids
5.3 Lubricants and operating fluids
5.3.1 Diesel fuels

Liebherr recommends the norm DIN EN 590.
Minimum quality requirements
Permitted diesel fuels on the basis of DIN EN 590 and ASTM D975 with
exception of:
Maximum sulphur content 5000 ppm
Lubricating ability at 60°C 460 µm
Minimum cetane number 45
Tab. 8: Minimum requirement for diesel fuels
5.3.2 Lubricating oil
Difficulty factors
Difficulty factors include:
– Repeated cold-starts
– Enviromental influences
• Application temperature
• Dust
• High humidity
If difficulty factors or difficult operating conditions exist, the oil and filter change
must be performed according to the following table.
International oil stand- Minimum quality require- Liebherr recommends

Difficulty factor
ards ments
ACEA E4, ACEA E7 LH-00-ENG3A Liebherr engine oil 5W-30
API CI-4, CI-4 Plus, CH-4 Liebherr engine oil 10W-40
Sulphur content in fuel Interval (h = operating hours)
up to 200 ppm 500 h 500 h 1000 h
over 200 ppm to 2000
500 h 500 h 500 h
ppm
LMB/11429440/00/01.12.2015/en
over 2000 ppm to 5000

125 h 250 h 250 h
ppm
Tab. 9: Oil change intervals in accordance with difficulty factors
Ensure that the following minimum requirements are met at 500 h:

–TBN (Total base number) > 6
–SiO (Soot in oil) < 1 %

LEC D9512 A7–00 / D9512 A7 Tier 2 /
2013160001 45
Lubricants and operating fluids
Liebherr recommends
Name
Liebherr engine oil 10W-40
Tab. 10: Recommendations for engine oils
Spezifikation
LH-00-ENG3A
Tab. 11: Minimum requirements engine oil
5.3.3 Coolant
Composition
Note
Mixing different corrosion frost protection agents can diminish the properties of the
coolant.
u Do not combine different products!
u Silicate-containing and silicate-free coolants may not be mixed under any
circumstances since this can lead to damage to the cooling system!
Requirements for water used

Make sure that the water used fulfils the following prerequisites:
– Applies to the guideline for drinking water of the world health organisation
(WHO) 2006
Corrosion frost protection agent
Liebherr recommends
Type Name
Concentrate Liebherr Antifreeze OS Concentrate
PremixA) Liebherr Antifreeze OS Mix
LMB/11429440/00/01.12.2015/en
Tab. 12: Recommendations for corrosion frost protection agent
A) Premix = ready mixture (50 % water and 50 % corrosion frost protection agent)
Spezifikation
LH-01-COL3A
Tab. 13: Minimum requirements coolant

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Special tools for maintenance tasks
5.4 Special tools for maintenance tasks
Fig. 18: Turning gear — Mounting the flywheel housing, special tool no. 30 and 30c
No. ID no. Description See section

30 9078688 Turning gear Check / adjust valve clearance
Hexagonal screw with
30c 10030519 Check / adjust valve clearance
flange M8 x 20
Tab. 14
Fig. 19: Turning gear — Mounting the flywheel housing, special tool no. 32
LMB/11429440/00/01.12.2015/en

32 10123791 Turning gear Check / adjust valve clearance
Tab. 15
Turning gear special tool no. 32 is only included and fitted within the diesel engine
scope in special cases.

LEC D9512 A7–00 / D9512 A7 Tier 2 /
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Special tools for maintenance tasks
Fig. 20: Angular measuring device kit

Angular measuring
33 10144884 Check / adjust valve clearance
device kit
Tab. 16
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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 specified otherwise in
the description.
Diverse maintenance tasks include for example:
– Checking of the oil level or oil change
– Replacing the filter, as well as adjustment and repair tasks.
Safety precautions for maintenance
It is imperative that the safety guidelines are observed when carrying out mainte-
nance tasks! Refer to the chapter “Safety guidelines”.
Maintenance points
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 to the ambient temperature.
– The battery main switch (if featured) is switched off and the key for the main
switch has been removed.
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Daily maintenance tasks (every 10 operating hours)
5.6 Daily maintenance tasks (every 10 oper-

ating hours)

q The diesel engine is in the maintenance position.
5.6.1 Checking the engine oil level

The oil dipstick and oil filler nozzles are arranged differently depending on the
respective diesel engine, for example oil dipstick arranged on the left-hand or right-
hand side of the engine. The oil filler nozzle is situated on the oil sump, flywheel
housing or on the cylinder head cover.
Fig. 21: Example oil dipstick - oil filler nozzle
u Pull out oil dipstick 1, wipe with a clean rag and insert again up to the stop.
u Pull out the oil dipstick once again and determine the oil level. The oil level must
be between “min.” and “max”.
If the oil level is too low:
u Remove oil filter cap.
u Fill in oil via the filler neck 2.
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.
5.6.2 Visual inspection (leaks, contamination, damage)

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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.

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5.6.3 Checking the coolant level
DANGER
Hot cooler components and hot refrigerants!
Risk of 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, refer to the documentation of the
machine manufacturer.
5.6.4 Checking / draining the water separator of the fuel

prefilter (variant 1)
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 of which varies in accordance with
respective configuration of the machine.
WARNING
Naked flames!
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 after the diesel engine has
been shut down.
Draining the fuel prefilter

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Fig. 22: Draining the fuel prefilter
u Check the water separator of the fuel prefilter.

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Water has been determined in the water separator of the fuel prefilter?
u Position collecting vessel beneath the water separator.
u Loosen the bleed screw 1 and turn around two full 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.
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).
Bleeding the fuel prefilter

Procedure for bleeding the fuel system if the manual delivery pump is
mounted in front of the fuel prefilter.
Fig. 23: Bleeding the fuel prefilter

1 Bleed screw 2 Manual aeration pump
u Turn the arrow-type rotary lock 2a in a clockwise direction as far as the stop.
u Continue to actuate the manual delivery pump 2b until bubble-free fuel flows out
at the bleed screw 1.
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u Tighten the bleed screw 1 with a tightening torque of 6 Nm.

u Turn the arrow-type rotary lock 2c in an anticlockwise direction as far as the
stop.
u Start the engine.

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Troubleshooting
The engine has still not started after approx. 20 seconds?
When this action has been repeated three times:
u Repeat the bleed procedure.
Note
u The low-pressure circuit (NDK) of the engine is bled by permanently installed
restrictor bores, no other additional measures are necessary.
mounted after the fuel prefilter.
u Continue to actuate the manual delivery pump 2b until a significant resistance
becomes evident.
Note
u Actuate the manual delivery pump 2b until the diagnosis tool shows 10,15 psi
on the channel 32180 FuelP1Val.

stop.
u Start the engine.
Troubleshooting
Note
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5.6.5 Checking / draining the water separator of the fuel

prefilter (variant 2)
Fig. 24: Fuel prefilter
u Correct procedure for checking / draining the water separator, refer to the docu-
mentation of the machine manufacturer.
5.6.6 Checking low-pressure display of the air filter

Procedure for checking the underpressure display for the air filter, refer to the
documentation of the machine manufacturer.
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Weekly maintenance tasks (every 50 operating hours)
5.7 Weekly maintenance tasks (every 50 oper-

ating hours)

5.7.1 Draining water and sediment in the fuel tank
WARNING
Naked flames!
been shut down.
Procedure for draining water and sediment in the fuel tank, refer to the docu-
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

Procedure for cleaning the dust-discharge valve of the air filter, refer to the docu-
LMB/11429440/00/01.12.2015/en

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Maintenance Tasks, every 250 operating hours
5.8 Maintenance Tasks, every 250 operating

hours
Only perform this maintenance, if application in Indonesia (or countries with

similar fuel quality).
5.8.1 Replacing the fuel prefilter element
u Correct procedure for replacing the fuel filter element, refer to the documenta-
tion of the machine manufacturer.
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5.8.2 Replacing the fuel fine-filter
Fig. 26: Fuel fine-filter
u Correct procedure for replacing the fuel fine-filter element, refer to the docu-
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5.9 Maintenance Tasks, every 500 operating

hours

5.9.1 Checking condition of the belt drive and replacing as

necessary.
Damage to the ribbed V-belt includes:
– 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.
Checking ribbed V-belt

u Inspect the ribbed V-belt for damage.
u Check pulleys and tensioning devices (tension pulley) for sound condition and
clearance.
Troubleshooting
Damage has been determined?
u Replace damaged parts.
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Replacing ribbed V-belt and tensioning device
Fig. 27: V-belt drive

q Two new ribbed V-belts are on-hand.
q Two new tensioning devices are on-hand.
q A socket and lever are on-hand.
u Fit the socket with lever on the corresponding tensioning device.
u Pivot back the tensioning device against the spring force in an anticlockwise
direction as far as the stop and remove the ribbed V-belt.
u Dismantle the tensioning device.
u Check pulleys for sound condition and clearance.
Troubleshooting
u Fit the new tensioning device (tightening torque 47+/- 5 Nm).

u With the tensioning device swung back, mount new ribbed V-belt onto all
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pulleys and tension pulleys ensuring a sound fit.

u Return the tensioning device into the tensioning position.

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5.9.2 Checking the 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.
5.9.3 Checking the cooling and heating systems for sound

condition and for leaks
DANGER
Hot cooler components and hot refrigerants!
Risk of 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.
u Check cooler for external contamination. The fins should not become clogged
with dirt.
Troubleshooting
Leaks are determined in the cooling system:
u Do not start the diesel engine.
u Remedy the cause.
5.9.4 Checking the lubrication system and fuel system for

leaks and for sound condition
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The diesel engine features a drainage bore through the crankcase bulkhead,
through which any liquids such as water, fuel etc. is channelled out to the V-
compartment.

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Fig. 28: V-compartment drainage bore
u Check oil sump, oil filter and fuel system 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 Determine and remedy the cause and replace any damaged parts.
5.9.5 Replacing the fuel prefilter element (variant 1)

q A fuel prefilter element is on-hand.
The fuel prefilter with water separator and fuel manual delivery pump is arranged
away from the diesel engine and features different mounting variations in accord-
ance with the respective configuration of the machine.
WARNING
Naked flames!
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been shut down.
If a fuel shut-off valve is featured:

u Close the fuel shut-off valve.

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u Position the collecting vessel beneath the fuel prefilter.

u Open the shut-off tap. For correct procedure, refer to 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.
WARNING
Risk of dirt!
Ruination of the Common Rail System.
u Ensure that no dirt penetrates the clean side of the filter.
u Leave any residual diesel fuel in the filter housing.
u Do not use fuel fine filters again once used.
u Refer to the special information regarding working on the Common Rail System,
see 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,
refer to the chapter “Bleeding the fuel system”.
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5.9.6 Replacing the fuel prefilter element (variant 2)
u Correct procedure for replacing the fuel filter element, refer to the documenta-
tion of the machine manufacturer.
5.9.7 Replacing the fuel fine-filter

q Two original LIEBHERR fuel fine filter elements are on-hand.
q A suitable drainage hose from the machine manufacturer is on-hand.
The fuel fine filters are located on top in the V-compartment of the diesel engine.
WARNING
Naked flames!
LMB/11429440/00/01.12.2015/en

been shut down.
If a fuel shut-off valve is featured:

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

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Fig. 31: Fuel drainage line
u Position the collecting vessel beneath the fuel drainage line.

u Clean the fuel service centre and the surrounding area thoroughly.
u Loosen the fuel drainage line using the screw mechanism 1.
Fig. 32: Replacing the fuel fine-filter

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u Loosen both housing covers 1 from the fuel service centre using a suitable tool.
Open the cover until the respective vent hole is freed.
u Wait until the fuel from the filter housing has drained out into the collecting
vessel.
u Dismantle both covers of the fuel service centre, including fuel fine filter
elements.
u Remove the fuel fine filter element 3 from the housing cover 1.
u Dispose of the used fuel fine filter elements.

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u Replace the sealing ring 2 and if necessary clean the housing cover.
WARNING
Risk of dirt!
u Ensure that no dirt penetrates the clean side of the filter.
u Leave residual diesel fuel in the filter housing.
u Do not use fuel fine filters again once used.
u Use new original LIEBHERR fuel fine filter elements.

u Screw in the fuel fine filter element with housing cover and tighten (tightening
torque 40+5 Nm).
u Lock the fuel drainage line using the screw mechanism.
u Open the fuel shut-off valve and bleed the fuel system. For correct procedure,
refer to the chapter “Bleeding the fuel system”.
5.9.8 Replacing the fuel fine-filter for remote mounted fuel

fine-filter
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Fig. 33: Fuel fine-filter
u Correct procedure for replacing the fuel fine-filter element, refer to the docu-

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5.9.9 Checking batteries and cable connections
Note
hours.
Procedure for checking the batteries and cable connections, refer to the documen-
tation of the machine manufacturer.
5.9.10 Checking the control unit mounting for sound condi-

tion
Note
hours.
If a kick plate is featured:

u Dismantle the kick plate.
u Check the control unit mounting for damage and secure fastening.
Troubleshooting
Damaged bearings have been determined?
u Replace all bearings.
5.9.11 Checking sensors, actuators, cable fittings and plugs

for sound condition
Note
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
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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 Replace faulty parts.

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Maintenance tasks every 1000 operating hours
5.10 Maintenance tasks every 1000 operating

hours

5.10.1 Changing diesel engine oil and replacing the oil filter
element
q The diesel engine is positioned horizontally.
q The diesel engine is warm.
q Original LIEBHERR oil filter elements with the seals are on-hand.
q A suitable drainage hose from the machine manufacturer is on-hand.
q Diesel engine oil is on-hand. Diesel engine oil filling amount, refer to the chapter
“Filling amounts”. For lube oil specification, refer to the chapter “Fuel and lubri-
cants”.
The oil drain valve is mounted on the diesel engine, either at the bottom or on the
side of the oil sump.
The oil filter modules are arranged on the left-hand and right-hand side of the
diesel engine, on the opposite side of the flywheel.
Draining the diesel engine oil

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Fig. 34: Oil filter
u Continue to unscrew the oil filter cover 1 until the upper O-ring becomes visible.

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CAUTION
Hot engine oil!
Risk of burns.
u Avoid skin contact with the engine oil.
u Wear protective industrial gloves when changing the oil.
Fig. 35: Oil drain valve
u Unscrew the sealing cap from the oil drain valve.

u Screw the oil drainage hose onto the oil drain valve and drain the oil into the
prepared collecting vessel.
u Dispose of the oil (for correct procedure, refer to the chapter “Disposing of used
materials”).
u Unscrew the oil drainage hose and screw the sealing cap onto the oil drain
valve.
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Replacing the oil filter element
Fig. 36: Oil filter element
u Remove the oil filter cover 1.

u Pull out the old oil filter element 3.
u Dispose of oil filter element (for correct procedure, refer to the chapter
“Disposing of used materials”).
u Install the new sealing ring 2.
u Insert the new oil filter element 3.
u Screw in the oil filter cover 1 and tighten with 150 Nm.
Filling diesel engine oil

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Fig. 37: Filling diesel engine oil

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u Remove the oil filter cap.

u Fill in oil via the oil filler nozzle 2 to within “min” and “max.” on the oil dipstick 1.
u Clean the oil filler cap, place onto the oil filler nozzle and tighten.
u Check oil pressure (diesel engine oil pressure display unit) and check seals on
the oil filter.
u Check the oil level after 2 - 3 minutes using the dipstick.
Troubleshooting
The oil level is not within “min.” and “max.”?
u Rectify the oil level.
5.10.2 Replacing the crankcase breather oil separator filter

element.
Only perform this maintenance, if application is with oil separator filter.
q Two new filter separator filter elements with new O-rings are on-hand.
The oil separators are arranged on the left-hand and right-hand side of the front of
the diesel engine, on the opposite side of the flywheel.
Dismantling the oil separator filter element
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Fig. 38: Dismantling the filter element
u Pull out the hose clamps 1 and hose 2 from the regulating valve (cover) 4.

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u Loosen the screws 3.

u Remove the regulating valve (cover).
u Remove the filter element 6.
Installing the oil separator filter element
Fig. 39: Installing the filter element
u Lubricate the O-ring 7 of the new filter element 6 with clean fuel or oil.
u Insert new filter element.
u Insert the new O-ring 5 at the regulating valve (cover).
u Lubricate the O-ring with clean fuel or oil.
u Fit the regulating valve (cover), alignment on aggregate carrier side (observe
the direction of streaming).
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Fig. 40: Filter element installed
u Fix the regulating valve with screws.

u Push on the hose and tighten the hose clamps.
5.10.3 Checking the oil sump, engine mount and diesel

engine brackets for secure seating
Fig. 41: Oil sump — engine brackets

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

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hours

5.11.1 Replacing the ribbed V-belt and tensioning device
Fig. 42: V-belt drive

q Two new ribbed V-belts are on-hand.
q Two new tensioning devices are on-hand.
q A socket and lever are on-hand.
u Fit the socket with lever on the corresponding tensioning device.
u Pivot back the tensioning device against the spring force in an anticlockwise
direction until the stop and remove the ribbed V-belt.
u Dismantle the tensioning device.
u Check pulleys for sound condition and clearance.
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Troubleshooting
u Fit the new tensioning device (tightening torque 47+/- 5 Nm).

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u With the tensioning device swung back, mount new ribbed V-belt onto all
pulleys and tension pulleys ensuring a sound fit.
u Return the tensioning device into the tensioning position.
5.11.2 Checking and adjusting valve clearance
Setting variant 1
q A special tool turning gear is on-hand. Refer to the chapter “Special tools for
maintenance tasks”.
q A feeler gauge is on-hand.
Note
Cylinder 1 is located on the opposite side of the flywheel on the right.
u Rotational direction to the left looking at the flywheel
Fig. 43: Valves of the cylinder

A = exhaust valve
E = intake valve
Valves of cylinders D9512

Overlap 1 12 2 11 3 10 6 7 5 8 4 9
Adjust 6 7 5 8 4 9 1 12 2 11 3 10
Tab. 17: Valves of cylinders D9512
u Remove the cylinder head covers.

u Mount the turning gear or use turning gear no. 32 already mounted.
u Continue to turn the crankshaft with turning gear in the direction of rotation until
the valves of the cylinder being adjusted overlap.
LMB/11429440/00/01.12.2015/en
Note
u For specifications, see the table “Valves of cylinder D9512”.

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Fig. 44: Checking / adjusting intake valve clearance
Fig. 45: Checking / adjusting exhaust valve clearance
u Insert feeler gauge between valve fitting and rocker arm and check valve clear-
ance.
Troubleshooting
The clearance does not correlate with the setting values (refer to the identification
plate)?
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
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with inspected and approved damage-free seals.

If the turning gear is not fixed:
u Dismantle the turning gear.
Setting variant 2

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Adjustment is performed in accordance with the following diagram:
Setting Intake valves for Exhaust valves for

°KW
position cylinder cylinder
1 TDC 1-4-8-9 1 - 2 - 3 - 9 - 11 - 12
2 TDC +360° 3 - 6 - 10 - 11 4 - 5 - 6 - 7 - 8 - 10
Valve overlap cylinder 3
3 5-7
(TDC +600°)
Intake valve cylinder 3 at
4 end of closing procedure 2 - 12
(TDC +900°)
Tab. 18: Valves to be adjusted for setting variant 2
The intake and exhaust valves are arranged as follows:

A = exhaust valve
E = intake valve
Note
Cylinder 1 is located on the opposite side of the flywheel on the right.
1st setting position “TDC”

u Turn the crankshaft with turning gear until cylinder 1 is in the TDC position
(valves of cylinder 6 overlap one another).
w Cylinder 1 in TDC position
w Valves of cylinder 6 overlap one another.
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Note
u TDC marking is located in the flywheel housing.
u The notch in the flywheel must be aligned (arrow) with the forefront of the metal
plate in the flywheel housing.

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Fig. 47: TDC marking cylinder 1
Note
u Valve clearance setting value, refer to the identification plate
Setting the valves:
Fig. 48
u Set / check intake valves 1 - 4 - 8 - 9.

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Fig. 49
u Set / check exhaust valves 1 - 2 - 3 - 9 - 11 - 12.

w All valves in the 1st setting position with TDC setting have been set /
checked.
Troubleshooting
plate)?
adjust the setting.
2nd setting position “TDC +360°”

u Turn the crankshaft around 360° in the rotational direction (+/-5°).
w All valves in the 2nd setting position with 360° have been set / checked.
Troubleshooting
plate)?
adjust the setting.
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3rd setting position “TDC +600°”

u Continue to turn the crankshaft in the rotational direction until the valves of the
3rd cylinder overlap one another (the setting position is at approx. 600°).
u Set / check intake valves 5 - 7.
w All valves in the 3rd setting position have been set / checked.

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Troubleshooting
plate)?
adjust the setting.
4th setting position “TDC +900°”

u Continue to turn the crankshaft in the rotational direction until the intake valves
of the 3rd cylinder are at the end of the closing procedure (the setting position is
at approx. 900°).
u Set / check intake valves 2 - 12.
w All valves in the 4th setting position have been set / checked.
Troubleshooting
plate)?
adjust the setting.

u Dismantle the turning gear (if not fixed).
Setting variant 3
q A special tool angle measuring device is on-hand. Refer to the chapter “Special
tools for maintenance tasks”
Adjustment is performed in accordance with the following diagram:
Intake valves for Exhaust valves for

Setting position °KW
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cylinder cylinder
1 TDC 1-4-8-9 1 - 2 - 3 - 9 - 11 - 12
2 TDC +310° 2 - 3 - 10 - 11 - 12 5 - 6 - 7 - 10
3 TDC +540° 5-6-7 4-8
Tab. 19: Valves to be adjusted for setting variant 3
The intake and exhaust valves are arranged as follows:

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A = exhaust valve
E = intake valve
Note
u Cylinder 1 is located on the opposite side of the flywheel on the right.
1st setting position TDC (+/- 5°)

u Turn the crankshaft with turning gear until cylinder 1 is in the TDC position
(valves of cylinder 6 overlap one another).
w Cylinder 1 in TDC position
w Valves of cylinder 6 overlap one another.
Note
u TDC marking is located in the flywheel housing.
u The notch in the flywheel must be aligned (arrow) with the forefront of the metal
plate in the flywheel housing.
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Fig. 51: TDC marking cylinder 1

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Note
u Valve clearance setting value, refer to the identification plate
Setting the valves:
Fig. 52
Fig. 53

w All valves in the 1st setting position with TDC setting have been set /
checked.
Troubleshooting
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plate)?
adjust the setting.
2nd setting position TDC +310° (+/-5°)


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u Set / check intake valves 2 - 3 - 10 - 11 - 12.

u Set / check exhaust valves 5 - 6 - 7 - 10.
w All valves in the 2nd setting position with 310° have been set / checked.
Troubleshooting
plate)?
adjust the setting.
3rd setting position TDC +540° (+/-5°)

u Set / check intake valves 5 - 6 - 7.
u Set / check exhaust valves 4 - 8.
w All valves in the 3rd setting position with 540° have been set / checked.
Troubleshooting
plate)?
adjust the setting.

If the turning gear is not fixed:
u Dismantle the turning gear.
5.11.3 Checking and correcting anticorrosive and antifreeze

concentrations in the coolant
Check the anticorrosive and antifreeze concentrations
DANGER
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Hot refrigerant!
Risk of 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 using an appropriate test procedure.
If the analysis yields a low frost protection:
u Adjust the mix ratio of the anticorrosive/antifreeze in the coolant.

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Correct adjustment of anticorrosive/antifreeze concen-

tration
If the anticorrosive/antifreeze concentration is too low:
u Drain the coolant and refill in accordance with the following anticorrosive/anti-
freeze calculation formula.
Coolant content
= 50 Litres → ↓
(overall)
Measured
= 29 Vol. % ↓
concentration
Refilling amount of anticorro-
↓ ↓
sive/antifreeze:
50 - 29 = 21 X 50 : 71 = 14.8 Litres
This amount should normally be
100 - 29 = 71 → ↑
drained first!
Tab. 20: Calculation formula for filling amount of anticorrosive/antifreeze, example 29 Vol.% (corresponds with
–15 °C)
Coolant must contain at least 50 %, however, no more than 60 Vol.% of anticorro-

sive / antifreeze all year round. A coolant with 50 Vol.% anticorrosive/antifreeze
corresponds with a freeze protection up to approx. °C . -37 °C.
NOTICE
Anticorrosive/antifreeze percentage in coolant too high!
Diesel engine is overheating and could sustain damage.
u Anticorrosive / antifreeze not to exceed 60%.
u For the correct filling amount of coolant, refer to the documentation of the
machine manufacturer.
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LEC D9512 A7–00 / D9512 A7 Tier 2 /
2013160001 83

hours
The components described as follows must be serviced or replaced at 7500 h

(Midlife kit, order number 10148226). Precise designations, such as replacement
part ID no. and amount are specified in the Liebherr documentation system
(LIDOS).
q The diesel engine is in the maintenance position and the corresponding
replacement parts are on-hand.
5.12.1 Crankcase aeration

Only perform this maintenance, if application is with oil separator filter.
Fig. 54: Crankcase aeration
Rubber coupling sleeves and oil separator (see Fig. “Crankcase breather”) must be
replaced.
LMB/11429440/00/01.12.2015/en
For correct procedure, refer to the repair manual for diesel engine D9512 A7.

LEC D9512 A7–00 / D9512 A7 Tier 2 /
84 2013160001
5.12.2 Replacing the fuel high-pressure pump
Fig. 55: Fuel high-pressure pump
Procedure for replacing the fuel high-pressure pump, refer to the repair manual of
diesel engine D9512 A7.
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LEC D9512 A7–00 / D9512 A7 Tier 2 /
2013160001 85
5.12.3 Injection nozzle / cylinder head cover seal
Fig. 56: Injection nozzle / cylinder head cover seal / pressure pipe tube
Procedure for replacing the injection nozzle / cylinder head cover seal, refer to the
repair manual for diesel engine D9512 A7.
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LEC D9512 A7–00 / D9512 A7 Tier 2 /
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5.12.4 Replacing the fuel injection lines
Fig. 57: Fuel injection lines
Procedure for replacing the fuel injection lines, refer to the repair manual of diesel
engine D9512 A7.
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LEC D9512 A7–00 / D9512 A7 Tier 2 /
2013160001 87
5.12.5 Replacing the water pump
Fig. 58: Water pump with seals
Procedure for replacing the water pump, refer to the repair manual for diesel
engine D9512 A7.
5.12.6 Replacing the coolant

q Heating taps, where featured, are open.
q A drainage hose is on-hand.
q The necessary amount of coolant is on-hand.
A coolant drain valve and a screw plug are located on the left-hand and right-hand
side of the crankcase opposite the flywheel.
Both drain valves and screw plugs must be opened for replacing the coolant.
Draining the coolant

LMB/11429440/00/01.12.2015/en
DANGER
Hot refrigerant!
Risk of burns.
u Before opening the filler neck, allow the engine to cool.
u Beware of overpressure when opening the filler neck.
u Do not fill the cooling system while the engine is still hot.

LEC D9512 A7–00 / D9512 A7 Tier 2 /
88 2013160001
Fig. 59: Draining the coolant
u Unscrew the sealing cap 1 in an anticlockwise direction until overpressure has

been dissipated, then open.
CAUTION
Coolant can cause injury to the eyes and lead to allergic skin reactions!
u Avoid skin contact with coolant.
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 of the drain valve on the left-hand or the right-hand
LMB/11429440/00/01.12.2015/en
side of the diesel engine.

u Screw the drainage hose onto the drain valve.
w The drain valve opens.
u Open the screw plug 3 on the same side on the crankcase.
u Open the drain plug on the cooler (refer to the documentation of the machine
manufacturer).
w The coolant from the oil cooler housing, the crankcase and the cooler flows
out into the container.

LEC D9512 A7–00 / D9512 A7 Tier 2 /
2013160001 89
u Once the coolant has drained, unscrew the drainage hose from the drain valve
and fit onto the drain valve on the opposite side, at the same time open the
screw plug 3 on this side.
u When the coolant has also drained from this side, unscrew the drainage hose
from the drain plug.
u Screw on both protective caps and fit the drain plug on the cooler and both
screw plugs on the crankcase.
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.
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.
u Check the coolant level again when the diesel engine has cooled and rectify as
necessary.
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LEC D9512 A7–00 / D9512 A7 Tier 2 /
90 2013160001

hours

5.13.1 Replacing the Visco-damper (vibration damper)
Fig. 60: Visco-damper
Procedure for replacing the Visco-damper, refer to the repair manual of diesel
engine D9512 A7.
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LEC D9512 A7–00 / D9512 A7 Tier 2 /
2013160001 91
Maintenance tasks as required
5.14 Maintenance tasks as required

5.14.1 Checking the heater flange

q An ohmmeter or a multimeter is on-hand.
The heater flange is mounted on the inlet of the air induction pipe on the right-hand
and left-hand side of the diesel engine opposite the flywheel.
Fig. 61: Heater flange

1 Heater flange
If a battery main switch is featured:
u Switch off the battery main switch 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 resist-
ance.
Troubleshooting
A resistance value of 0.25 Ohm +/- 10% at 20 °C was not attained?
u Replace the heater flange.
u Connect the electrical connecting cable on the heater flange, as well as the
negative cable from the battery.
LMB/11429440/00/01.12.2015/en
5.14.2 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

LEC D9512 A7–00 / D9512 A7 Tier 2 /
92 2013160001
WARNING
Risk of dirt!
u No injection lines may be opened or loosened.
u Ensure absolute cleanliness for all tasks.
WARNING
Naked flames!
been shut down.
mounted in front of the fuel prefilter.
Fig. 62: Bleeding the fuel prefilter

1 Bleed screw 2 Manual aeration pump
LMB/11429440/00/01.12.2015/en
u Loosen the bleed screw 1 and turn around two full turns (in an anticlockwise
direction).
u Continue to actuate the manual delivery pump 2b until bubble-free fuel flows out
at the bleed screw 1 .
stop.

LEC D9512 A7–00 / D9512 A7 Tier 2 /
2013160001 93
u Start the engine.
Troubleshooting
mounted after the fuel prefilter.
The bleed screw 1 is closed.
u Continue to actuate the manual delivery pump 2b until a significant resistance
becomes evident.
Note
u Actuate the manual delivery pump 2b until the diagnosis tool shows 10,15 psi
on the channel 32180 FuelP1Val.

stop.
u Start the engine.
Troubleshooting
Note
5.14.3 Extracting a sample of engine oil

Procedure for extracting a sample of oil:
Ensure that:
LMB/11429440/00/01.12.2015/en
q The diesel engine is warm.

q An appropriate oil sampling hose is on-hand.
CAUTION
Hot engine oil!
u Do not unscrew the oil sampling hose while the engine is running.
u Avoid skin contact with the engine oil.

LEC D9512 A7–00 / D9512 A7 Tier 2 /
94 2013160001
Fig. 63: Oil sampling point

1 Oil sampling point 2 Sealing cap
u Unscrew the sealing cap 2.
u Screw on the oil sampling hose (M16×1.5)
w Engine oil flows through the oil sampling hose into the container.
As soon as the required amount of engine oil has flowed into the container:
u Switch off the engine.
u Unscrew the oil sampling hose.
u Screw on the sealing cap 2.
5.14.4 Replacing the dry air filter main element

Correct procedure for replacing the dry air filter main element, refer to the docu-
5.14.5 Replacing the dry air filter safety element

Correct procedure for replacing the dry air filter main element, refer to the docu-
LMB/11429440/00/01.12.2015/en

LEC D9512 A7–00 / D9512 A7 Tier 2 /
2013160001 95
Transport and storage
5.15 Transport and storage
5.15.1 Lifting gear
DANGER
Falling load!
Danger to life.
u Observe maximum weight for lifting points!
u Observe a maximum of a 10° deviation from vertical to the engine axis!
u Use Liebherr lifting traverse!
u Only use transport equipment to transport the engine with no additional attach-
ments!
u Take into account safety instructions / warning signs from the operating instruc-
tions of the lifting traverse!
u Do not work under suspended loads!
LMB/11429440/00/01.12.2015/en
Fig. 64: Suspension device

LEC D9512 A7–00 / D9512 A7 Tier 2 /
96 2013160001
Fig. 65: Lifting gear
Note
Lifting traverse ID no. 10815480
u Before commissioning the lifting traverse, carefully read and observe the
description provided in the scope of delivery and the safety instructions
contained in this.
5.15.2 Storage up to 6 months

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 air can circulate around the diesel engine, thus preventing any conden-
sation forming.
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.
LMB/11429440/00/01.12.2015/en
5.15.3 Storage for between 6 and 24 months

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

LEC D9512 A7–00 / D9512 A7 Tier 2 /
2013160001 97
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LEC D9512 A7–00 / D9512 A7 Tier 2 /
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Index
Checking the cooling and heating systems for sound
condition and for leaks 60
Checking the engine oil level 50
Checking the heater flange 92
Checking the induction and exhaust gas system for
sound condition and for leaks 60
Checking the lubrication system and fuel system for
leaks and for sound condition 60
Checking the oil sump, engine mount and diesel
engine brackets for secure seating 72
1 Cleaning the dust-discharge valve of the air filter 55
1st setting position TDC (+/- 5°) 80 Cold start package 17
Composition 46
Control and operating elements 29
2 Coolant 46
2nd setting position TDC +310° (+/-5°) 81 Coolant pump 18
Coolant thermostat 19
Cooling 16
3 Cooling system 42
3rd setting position TDC +540° (+/-5°) 82 Correct adjustment of anticorrosive/antifreeze
concentration 83
Corrosion frost protection agent 46
4 Crankcase aeration 84
Cylinder designation, rotational direction 14
Cylinder head - valves 42
A Cylinder head, standard 18
Additional rules and regulations 22
Air filter 43
Air-conditioning compressor 17
D
Daily maintenance tasks (every 10 operating
hours) 50
B Design 15
Bleeding the fuel prefilter 52 Design features 15
Bleeding the fuel system 92 Designation of warning information 21
Diesel engine 18, 42
Diesel engine identification plate 13
C Diesel engine number 13
Changing diesel engine oil and replacing the oil filter Diesel fuels 45
element 67 Difficulty factors 45
Check the anticorrosive and antifreeze Dismantling the oil separator filter element 70
concentrations 82 Disposal of operating fluids 28
Checking / draining the water separator of the fuel Draining the coolant 88
prefilter (variant 1) 51 Draining the diesel engine oil 67
Checking / draining the water separator of the fuel Draining the fuel prefilter 51
prefilter (variant 2) 54 Draining water and sediment in the fuel tank 55
Checking and adjusting valve clearance 74 Drive control 15
Checking batteries and cable connections 66 Drive mechanism 15
Checking condition of the belt drive and replacing as
LMB/11429440/00/01.12.2015/en
necessary. 58
Checking correcting anticorrosive and antifreeze
E
concentrations in the coolant 82 Electrical system 43
Checking low-pressure display of the air filter 54 Electronic diesel engine regulation 16
Checking ribbed V-belt 58 Electronic sensors on the engine side 16
Checking sensors, actuators, cable fittings and plugs Engine classification 12
for sound condition 66 Engine control unit identification plate 14
Checking the control unit mounting for sound Engine oil sampling point 16
condition 66 Explanation of type description 12
Checking the coolant level 51 Extracting a sample of engine oil 94

LEC D9512 A7–00 / D9512 A7 Tier 2 /
2013160001 99
Index Operator's manual
F Notes on safety 21
Notes on the prevention of crushing and burns 23
Faults - Cause - Remedy 35 Notes on the prevention of fire and explosions 23
Features 15
Fill quantities 44
Filling diesel engine oil 69 O
Filling in coolant 90 Observe the safety precautions for diesel engines
Filling in fuels 30 featuring electronic control units 25
Flywheel housing 19 Observing the safety precautions upon start-up 23
Fuel system 42 Operation 30
Fuel system in application in Indonesia (or countries Operation, servicing 29
with similar fuel quality) 42 Overview of assembly 9
Further designations 22
P
G Preparations prior to initial start-up 30
General notes on safety 22 Preparatory maintenance tasks 49
Generator 19 Product Description 9
H R
Housing 15 Replacing ribbed V-belt and tensioning device 59
Replacing the coolant 88
I Replacing the crankcase breather oil separator filter
element. 70
Index 99 Replacing the dry air filter main element 95
Initial start-up / test run 30 Replacing the dry air filter safety element 95
Injection nozzle / cylinder head cover seal 86 Replacing the fuel fine-filter 57, 63
Injection system 16 Replacing the fuel fine-filter for remote mounted fuel
Installing the oil separator filter element 71 fine-filter 65
Replacing the fuel high-pressure pump 85
L Replacing the fuel injection lines 87
Replacing the fuel prefilter element 56
Liebherr recommends 46, 46 Replacing the fuel prefilter element (Variant 1) 61
Lifting gear 96 Replacing the fuel prefilter element (Variant 2) 63
Lubricants and operating fluids 45 Replacing the oil filter element 69
Lubricating oil 45 Replacing the ribbed V-belt and tensioning device 73
Lubrication 15 Replacing the Visco-damper (vibration damper) 91
Replacing the water pump 88
M Requirements for water used 46
Maintenance 41
Maintenance and inspection chart 41 S
Maintenance tasks as required 92 Safety and emergency run program for diesel engines
Maintenance tasks every 1000 operating hours 67 featuring electronic control units 26
Maintenance tasks every 15000 operating hours 91 Setting variant 1 74
LMB/11429440/00/01.12.2015/en

Maintenance Tasks, every 250 operating hours 56 Special equipment for the diesel engine 17
Maintenance Tasks, every 500 operating hours 58 Special notes regarding tasks on the Common Rail
Malfunctions 35 System 26
Measures for safe maintenance 24 Special tools for maintenance tasks 47
Midlife 43 Starter 19
Minimum quality requirements 45, 46, 46 Starting in frosty temperatures 32
Mounting options for pumps 16 Starting the diesel engine. 31
Storage for between 6 and 24 months 97
N Storage up to 6 months 97
Switching off the diesel engine. 32

LEC D9512 A7–00 / D9512 A7 Tier 2 /
100 2013160001
Operator's manual Index
T
Tasks to be performed following the test run 31
Technical data 18
Technical description 9
Test run 30
Transport and storage 96
U
V
Visual inspection (leaks, contamination, damage) 50
W
Weekly maintenance tasks (every 50 operating
hours) 55
LMB/11429440/00/01.12.2015/en

LEC D9512 A7–00 / D9512 A7 Tier 2 /
2013160001 101
Index Operator's manual
LMB/11429440/00/01.12.2015/en

LEC D9512 A7–00 / D9512 A7 Tier 2 /
102 2013160001

Manual Del Operador Ingles

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en Operator's manual

copyright © LIEBHERR MACHINES BULLE S.A. 01.1

copyright © LIEBHERR MACHINES BULLE S.A. 01.1

copyright © LIEBHERR MACHINES BULLE S.A. 01.1

copyright © LIEBHERR MACHINES BULLE S.A. 01.1

3.1 Control and operating elements 29

5.7.2 Cleaning the dust-discharge valve of the air filter 55

copyright © LIEBHERR MACHINES BULLE S.A. 01.1

5.13 Maintenance tasks every 15000 operating hours 91

copyright © LIEBHERR MACHINES BULLE S.A. 01.1

5.14.4 Replacing the dry air filter main element 95

copyright © LIEBHERR MACHINES BULLE S.A. 01.1

1.1 Technical description

1.1.1 Overview of assembly

copyright © LIEBHERR MACHINES BULLE S.A. 01.1

copyright © LIEBHERR MACHINES BULLE S.A. 01.1

copyright © LIEBHERR MACHINES BULLE S.A. 01.1

1.1.2 Explanation of type description

12 Number of cylinders: 12 = 12 cylinders

Tab. 1: Engine classification

copyright © LIEBHERR MACHINES BULLE S.A. 01.1

Diesel engine identification plate

Fig. 5: Identification plate

Diesel engine number

Fig. 6: Diesel engine number

copyright © LIEBHERR MACHINES BULLE S.A. 01.1

Engine control unit identification plate

Fig. 7: Example of identification plate for an engine control unit

Note The information on the engine control unit identifi-

Cylinder designation, rotational direction LMB/11429440/00/01.12.2015/en

Fig. 9: Cylinder designation / rotational direction

copyright © LIEBHERR MACHINES BULLE S.A. 01.1

1.1.3 Design features

copyright © LIEBHERR MACHINES BULLE S.A. 01.1

Engine oil sampling point

Fig. 10: Oil sampling point

Electronic diesel engine regulation

Electronic sensors on the engine side

Mounting options for pumps

copyright © LIEBHERR MACHINES BULLE S.A. 01.1

1.1.4 Special equipment for the diesel engine

Cold start package

copyright © LIEBHERR MACHINES BULLE S.A. 01.1

1.2 Technical data

1.2.1 Diesel engine

Description Unit Value

1.2.2 Cylinder head, standard

Description Unit Value

1.2.3 Coolant pump

Description Unit Value

copyright © LIEBHERR MACHINES BULLE S.A. 01.1

1.2.4 Coolant thermostat

Description Unit Value

Description Unit Value

Description Unit Value

1.2.7 Flywheel housing

Description Unit Value

copyright © LIEBHERR MACHINES BULLE S.A. 01.1

copyright © LIEBHERR MACHINES BULLE S.A. 01.1

2.1.1 Designation of warning information

This is a warning sign. It warns against potential risks of injury. All

DANGER Signifies an imminent hazardous situation which

CAUTION Signifies a dangerous situation which can result