Liebherr-Component Technologies

Diesel engines
from Liebherr
Liebherr-Component Technologies AG, with headquarter in Bulle, Switzerland, is responsible for all activities involving the
components sector within the Liebherr Group. The companies and corporate units belonging to this sector are specialized
in the development, design, manufacture and reconditioning of high performance components in the field of mechanical,
hydraulic, and electrical drive as well as control technology.

Long Years of Experience

Liebherr has decades of experience in the field of top qua-
System Solutions from One Source
Components from Liebherr are perfectly matched to one
Strong, powerful and reliable
lity components, for use in cranes, construction machine- another in their functional performance, and in combina-
ry, in the mining industry, maritime applications, wind tur- tion they achieve maximum total levels of effect and effi-
bines, automotive engineering, the aerospace sector, and ciency. Depending on the requirement, individual compo-
in transport technology. Synergy effects from the other nents from the broad product selection can be extended
product sectors of the Liebherr Group of Companies are up to the complete drive train. This creates system solu-
put to rational use in driving ahead with constant techno- tions with real conviction, which can be integrated into a
logical further development. whole range of applications.

The Right Solution for Every Need

Thanks to the in-depth manufacturing techniques and Quality and Cutting Edge
the use of the most modern and flexible production re- Technologies
sources, Liebherr can provide customers with tailor-made All components meet the highest demands for functional
solutions. Every component is developed to meet indivi- reliability and long service life, even under the toughest
dual wishes and requirements. Liebherr is your partner conditions. A refined quality management and extensive
for achieving success together, from the product idea to inspection and testing procedures are applied throughout
development, manufacture, and taking into service, and the entire development and manufacturing process. So
right on up to series manufacture. For the mechanical and they ensure the reliability and long life of the components.
hydraulic drive train components Liebherr offers recondi- Highly qualified staff with a real sense of responsibility plays
tioning in different stages from a specialised works. their part in achieving the fine Liebherr quality standard.

www.liebherr.com

Biberach: large diameter bearings, gearboxes, Lindau: electronics Kirchdorf: hydraulic cylinders
control technology

Bulle: diesel engines, splitter boxes, hydraulics Ettlingen: exchange components Monterrey: large diameter bearings

Printed in Germany by DWS BK LMB 11005234-1.5-03.10enGB Subject to technical modifications.

Liebherr Machines Bulle S.A.

45, rue de l’Industrie, CH-1630 Bulle
 +41 (0)26 913 3111, Fax +41 (0)26 913 34 85
www.liebherr.com, E-Mail: [email protected]
 Performance Environmental acceptance
Liebherr diesel engines have a high specific power With their intelligent electronic concept combined
output and ample torque over a broad engine speed with state-of-the-art fuel injection and exhaust gas re-
range; their other operating data are excellent too. circulation, Liebherr diesel engines comply with cur-
rent emission limits and are prepared to satisfy future
Reliability ones. The Liebherr diesel particulate filter reduce fine
Liebherr’s know-how, acquired over many years, dust emissions by more than 97 %. Electronic engine
and the constant improvement process made pos- management is matched to the machine concerned
sible by the use of the newest simulation and com- and includes a reliable, automatic filter regeneration
puting methods, are the key to the excellent reli- mode. Thanks to high-quality materials and well-
ability and long, trouble-free operating life of these planned design, the Liebherr diesel particulate filter
diesel engines in a wide variety of applications. has an extremely long operating life.

Smooth, quiet running Maintenance and servicing

The crankcases of the fully balanced 6-, 8- and Good access to servicing points and provision for
12-cylinder engines are acoustically optimised; electronic diagnosis make maintenance work on
the 4-cylinder engines have two balancer shafts. Liebherr’s highly developed diesel engines quick
These measures keep vibration and noise levels to and reliable. Spare part availability is guaranteed
a minimum, for smooth, refined operation. worldwide through the Liebherr Service network.

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 Performance
Notable features of Liebherr diesel engines are their ultra-modern technologies
and sound workmanship. They withstand even the most severe conditions,
guarantee reliable operation within a very wide outside temperature range and,
since their fuel injection control system taking account of air pressure, can
be used at high altitudes. High torque is available over a broad engine speed
range, so that the engines can run efficiently and with minimum power loss
even at very slow speeds, for exceptionally low noise levels and outstanding
fuel economy.

Fuel consumption An optimised development process using the lat-

est simulation methods results in leading-edge
fuel consumption figures.
Adaptability Many highly flexible applications provide highly
efficient solutions for every power requirement.

Modular systems Liebherr diesel engines are built according to a

modular system: various power take-offs can be
added to suit the intended task exactly.

Electronic engine management Common rail fuel injection 350 2000

Engine performance
325 1900 characteristics
• The system developed by Liebherr • Common rail systems from 300 1800
satisfies the most extreme demands Liebherr build up a very high • With the latest electronics, all
275 1700
pressure for fine atomisation components generously dimen-
• Highly flexible, can take many
of the fuel reaching the com-
250 1600
sioned and ample torque for
different factors into account

Torque (Nm)
Power (kW)
bustion chambers 225 1500
all purposes, these engines are
• Adaptable: the control module is 200 1400 ideal for every application
• Maximum flexibility, with
integrated into a complete end- 175 1300
a timing control system • High torque even at low engine
stage system 150 1200
speeds is the key to economy
• Based on tried and tested 125 1100
900 1100 1300 1500 1700 1900 2100 and exceptionally quiet running
solutions, for guaranteed Crankshaft (rpm)
long operating life
Performance group 1
Performance group 5

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 Reliability
Liebherr can rely on many decades of successful diesel engine design and the
experience gained by operating these engines in the most arduous imaginable
working conditions. Integrated functions and the reduced number of parts in
each engine are among the secrets of their excellent reliability.

Design Optimised crankcase design helps to make

Liebherr diesel engines exceptionally strong, sta-
ble and rigid. To accommodate the trend toward
higher combustion pressures, measures have
been taken to maintain these engines’ reputation
for long life.
Construction The very latest machine tools permit very close
tolerances and surface finishes of truly excellent
quality.
Operating life Liebherr engines are noted for their high life ex-
pectancy. Extensive rig tests and field trials in
realistic conditions are conducted with a view to
maintaining this proud reputation.

Pistons Connecting rods Bearings

• Increased combustion pressures call • Optimised design keeps maxi- • As combustion pressures
for radical measures to ensure compo- mum stresses low and increas- rise, the very latest materi-
nents’ long-term operating reliability es the built-in reserves of safety als are needed to guarantee
(for example single-piece steel pistons) the long life of components
• Careful load distribution makes
such as these, which are
• Development work using the latest better use of the properties of
subject to wear. The multi-
simulation programs keeps thermal the material
layer bearing shells are
loads well below critical levels
• Perfect geometry combines given a special coating for a
• Ingenious design ensures even more strength with minimum mass further increase in their load
efficient piston cooling capacity

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 Smooth running
All mechanical components for Liebherr diesel engines have been optimised to
keep vibration and noise levels to a minimum. With specific design measures,
reinforcement at the sides and a cross-connection at the bottom, the crank-
cases for all engine series achieve uniquely high levels of rigidity and set new
standards in terms of low noise. The 4-cylinder engines also have balancer
shafts to eliminate dynamic forces and reduce vibration still further.

Low vibration Special attention has been devoted to dynamic en-

gine components, to provide the optimal answer in
every load situation.
Dynamic response Well-planned electronics, ideal mass and opti-
mised forced-aspiration systems are the key to the
engines’ vigorous response to every demand.

FEM engine block analysis Balancer shafts Drive to auxiliaries

• The very latest analytical methods and op- • These additional mechani- • Where possible, auxiliary
timised rigidity have reduced vibration and cal devices counteract the equipment is driven by
noise levels even further residual dynamic forces in gearwheels in order to keep
four-cylinder engines maintenance demands low
• Analysis led to ideal standards of rigidity,
optimal mass distribution and improved • The extremely low level of • If belt drives are used,
geometry vibration greatly reduces they have an automatic
noise emissions tensioning system

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 Environmental acceptance
The following design features guarantee compliance with current and future
exhaust emission legislation:

• A fuel injection system with very high but adaptable pressure levels, to reduce
particulate emissions.

• Provision for exhaust gas recirculation in order to reduce emissions of oxides

of nitrogen.

• Electronic engine management using a large number of parameters for opti-

mal performance.

• Modern, efficient forced aspiration for an extended operating range. The en-
gines are designed to operate at very high combustion pressures as a means
of achieving optimal thermodynamic efficiency.

Innovative solutions Well-planned solutions simplify construction and

improve reliability.
Materials Despite increased loads on the reciprocating com-
ponents, new materials have increased the poten-
tial operating life of Liebherr’s diesel engines.
Electronic control Many years of experience and feedback from
customers are incorporated into Liebherr engine
management systems.

Cylinder head Exhaust gas recirculation Two-stage turbocharger

• These engines are strongly constructed to make • Lower combustion temperatures • Increased operating range
them suitable for the high combustion pressures and therefore reduced exhaust at optimal efficiency
that guarantee efficient use of fuel emissions • Higher torque over a larger
engine speed range
• Six cylinder head studs ensure reliable distribu- • Accurate system control avoids
tion of pressure loads and absolute freedom adverse effects on fuel consump- • Protected against over-
from pressure losses tion and complies with all statu- speeding although high
tory requirements pressures are used
• Four valves per cylinder permit higher combus-
tion air throughputs and minimise pressure loss • Even more dynamic
power flow

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 Module 1
Tier IIIB
Environmental acceptance
Purified exhaust gas Particulate filter with HC doser
from engine and thermal management
Exhaust post-treatment with the
Liebherr particulate filter:
This is a filter system specially developed by Liebherr for tough construction-
Input module site conditions. It traps more than 97 % of the relevant particles (VERT-certified)
(with DOC for additional and has a complete double-walled housing with 10 mm thick heat insulation to
temperature increase)
protect other components in the engine compartment and eliminate fire risk. It
is absolutely leakproof, thanks to the use of advanced sealing technology, so
that no pollutants can escape before reaching the filter element. The filter is inte-
grated into the engine compartment and does not obstruct the operator’s view.
Temperature
measurement
Convenient operation
Temperature The centre module can be removed for servicing even after a lengthy period
measurement of operation, thanks to its patented sealing rings. The filter element can be
changed quickly and easily by loosening two retaining clips. There are fixed
holders to ensure that the filter module is always installed correctly. Untreated
exhaust gas is measured on the diesel engine at unions on the input pipe; the
filter does not have to be removed.

Economy
Output module
Liebherr particulate filters are notable for lengthy operating periods before
cleaning is needed. The filter module is then removed and burned clean. The
filters have a long overall operating life that matches the machine in which the
engine is installed. If maintenance takes place regularly, the filter module will not
need to be renewed prematurely.
Exhaust
from engine

Module 2: Pressure measurement

System for Tier IV
- Particulate filter
- SCR systems

Technical data Filter cleaning Regeneration during

operation
• Liebherr particulate filters are closed sys- Engine oil combustion residues
tems using a coated ceramic filter element that remain in the filter despite Particles are oxidised by con-
active and passive regeneration tinuous passive regeneration
• Thermal management system guarantees
have to be removed. This is true whenever the exhaust gas
much-extended cleaning intervals
of all such systems on the market. temperature is above 250 °C.
• Four sizes available (9, 10.5, 12 or 15 inch), After 3,000 – 4,500 hours of op- If this temperature is not
depending on engine power output eration, the filter must be cleaned reached, an active regenera-
by trained Liebherr staff. The use tion process is started; this
• Filter systems with radial or axial connec-
of Liebherr “10W-40 low ash” en- takes place without interrupt-
tions to suit the installation situation
gine oil can prolong the cleaning ing engine operation.
intervals.

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 Maintenance and servicing
A clearly defined concept has been adopted to simplify maintenance work.
Items of equipment are easily located and the descriptive documentation well
planned to make the work easier. High-tech diagnostic tools, programs that
can be carried out intuitively and regular training enable our skilled staff to per-
form maintenance work efficiently and in the shortest possible time. Repair kits
based on practical needs have been compiled as a means of keeping machin-
ery operational whenever possible.

Training So that everyone who works with Liebherr prod-

ucts is well equipped for the task, Liebherr holds
practically-oriented basic training courses, with
equipment that enables even extreme situations
to be simulated.
Optimal access To keep maintenance as straightforward as possi-
ble, special care has been taken to make all com-
ponents easily accessible and clearly laid out.

Diagnostic tools Availability of spare parts Training

• Electronic diagnostic tools permit simple, • The Liebherr Group’ Service • Liebherr’s service staff is
rapid location of malfunctions and faults network guarantees world- given practically oriented
wide availability of spare training and is therefore
parts capable of providing com-
petent, expert customer
• Repair kits simplify parts
support in every situation.
handling and ensure high-
quality repairs

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 D934 A7 D936 A7 D946 A7 D9508 A7 D9512 A7
Layout 4 inline 6 inline 6 inline 8 in V 12 in V
Displacement [cc] 7 10.5 11.9 16.2 24.2
Bore [mm] 122 122 130 128 128
Stroke [mm] 150 150 150 157 157
Dry weight [kg] 1018 1214 1341 1625 2050
Dimensions (L x W x H) [cm] 1173 x 918 x 1131 1592 x 903 x 1151 1692 x 1112 x 1350 1692 x 1112 x 1350 1856 x 1236 x 1314
Nominal power output [kW]
160 - 200 240 - 300 300 - 390 400 - 500 565 - 750
(acc. to performance group)
Nominal engine speed [1/min] 1800 - 2100 1800 - 2100 1800 - 2100 1800 - 2100 1800 - 2100
Power take-off 4 4 4 3 1
Flywheel housing SAE 1/ SAE 2 SAE 1/ SAE 2 SAE 1 SAE 1 SAE 0
Air compressor Optional Optional Optional Optional -
Air conditioning compressor Optional Optional Optional Optional Optional
97/68 EG Stufe IIIB 97/68 EG Stufe IIIB 97/68 EG Stufe IIIB 97/68 EG Stufe IIIB USA EPA Tier 2
Exhaust emission levels
EPA CARB TIER 4i EPA CARB TIER 4i EPA CARB TIER 4i EPA CARB TIER 4i and TIER 4i compliant
Power output and torque 260 1400 350 2000 500 3250 550 3750 800 5000

240 1300 325 1900 450 3000 500 3500

700 4500
220 1200 300 1800 400 2750 450 3250
600 4000
200 1100 275 1700 350 2500 400 3000

Torque (Nm)

Torque (Nm)

Torque (Nm)

Torque (Nm)

Torque (Nm)
Power (kW)

Power (kW)

Power (kW)

Power (kW)

Power (kW)
180 1000 250 300 2250 350 2750 500 3500
1600

160 900 225 1500 250 2000 300 2500 400 3000

140 800 200 1400 200 1750 250 2250

300 2500
120 700 175 1300 150 1500 200 2000
200 2000
100 600 150 1200 100 1250 150 1750

80 500 125 1100 50 1000 100 1500 100 1500

900 1100 1300 1500 1700 1900 2100 900 1100 1300 1500 1700 1900 2100 900 1100 1300 1500 1700 1900 2100 900 1100 1300 1500 1700 1900 2100 900 1100 1300 1500 1700 1900 2100

Crankshaft (rpm) Crankshaft (rpm) Crankshaft (rpm) Crankshaft (rpm) Crankshaft (rpm)

Performance group 1 Performance group 1 Performance group 1 Performance group 1 Performance group 1
Performance group 5 Performance group 5 Performance group 5 Performance group 5 Performance group 5

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 Drive assembly
AG936
270 kW (1500 - 1800 1/min)

1 multi-output transmission
2 open-circuit pumps
1 closed-circuit pump
1 low-pressure pump
1 gear-type pump

Multi-circuit unit Hydraulic pumps and motors Pilot control devices

MKA 450 D The extensive programme of Hand- or foot-operated
Power rating 504 kW products for open and closed hydraulic pilot control
3 axial pumps circuits covers a very large devices
250 cc/rev range of delivery volumes.
1 axial pump
75 cc/rev

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