Reconstruction of the Liebherr D926 TI-E Engine in the LTM 1045-3.1 Crane

Introduction

The mobile crane Liebherr LTM 1045-3.1 is a versatile all-terrain crane that combines high mobility with significant lifting capabilities. This machine is equipped with the Liebherr D926 TI-E engine, a six-cylinder diesel unit known for its durability and high power. The machine was brought to our service near Katowice, where the operator reported issues with power loss and unusual smoking during operation. Preliminary diagnostics indicated wear on the cylinders and pistons, necessitating a complete overhaul of the unit.

Engine Disassembly

Our mobile service performed the engine disassembly directly at the client's site. First, the electrical systems, fuel lines, and cooling system were disconnected. Components such as the turbocharger and alternator were removed, and the intake and cooling systems were protected from contamination. With the help of a crane provided by the client, the power unit was removed from the crane's frame and transported to our headquarters in Kojszówka.

Component Verification

The engine was disassembled into its individual parts, and all components were cleaned and inspected in detail. The verification confirmed significant wear on the pistons and cylinder liners, resulting in a drop in compression. Additionally, increased clearance on the crankshaft bearings was noted. We conducted an examination of the crankshaft, inspected the cylinder head for leaks, and checked the condition of the turbocharger and injection pump.

Regeneration and Repair

Crankshaft-Piston System

The cylinder liners were replaced with new ones, and the pistons with a complete set of rings were installed after proper fitting. The crankshaft was ground, and repair bearings were selected. The connecting rods were checked for straightness and weight.

Engine Head

The cylinder head underwent a leak test in a water bath. Subsequently, it was planed, and guides and valves were replaced. Valve seals were also replaced with new ones.

Fuel System

The injection pump was sent for regeneration to a specialized facility. The injectors were tested on a test bench, and the end elements were replaced. The fuel pump was regenerated in our workshop.

Accessories

The turbocharger was inspected for clearances and regenerated. The starter and alternator were tested, and the bearings were replaced. Additionally, part of the intake and oil system piping was modernized to ensure maximum sealing.

Engine Installation

After fully assembling the engine and setting all clearances according to the manufacturer's specifications, the unit was reinstalled in the LTM 1045-3.1 crane. The process included connecting all electrical wires, fuel lines, cooling, and air systems. We checked the tightness of all connections and then started the engine in the presence of the operator. During operational tests, we performed dynamic tests of the machine, ensuring that the drive operated smoothly and without leaks. The culmination of the work was the signing of the acceptance protocol.

Engine Test on the Dynamometer

One of the greatest advantages of our service is having our own engine dynamometer. The Liebherr D926 TI-E engine underwent load testing even before installation in the machine. The test lasted over 16 hours and included a light load phase (20-30% of nominal power), followed by full work cycles with varying loads. This allowed us to confirm correct oil pressure values, operating temperatures, and smooth operation across the entire RPM range. The dynamometer enabled us to detect and correct minor leaks in the fuel system before the engine returned to the crane, significantly increasing the reliability of the entire unit.

This solution ensures that clients receive an engine not only after complete regeneration but also tested under conditions close to real-world usage. In the construction machinery service industry, few companies can boast such technological capabilities, giving us an advantage and a guarantee of quality.

Engine Maintenance After Overhaul

Every engine after overhaul at WIBAKO is covered by a warranty. We recommend the first filter change after 50 operating hours and a full system inspection performed by our mobile service. Subsequent inspections should occur every 250 operating hours or every 3 months, depending on usage intensity. This way, the LTM 1045-3.1 crane can operate safely and reliably for a long time.

Other Machines with Liebherr D926 TI-E Engine

The Liebherr D926 TI-E engine is used not only in mobile cranes but also in crawler cranes and some handling machines. Due to its versatility and durability, it is a popular choice by the manufacturer for heavy applications.

Summary

The overhaul of the Liebherr D926 TI-E engine in the Liebherr LTM 1045-3.1 crane restored the machine's full functionality and ensured its continued safe operation. Thanks to the dynamometer, we were confident that the unit met all factory parameters, and the client received a guarantee of trouble-free operation. This comprehensive approach ensures that WIBAKO service enjoys the trust of clients throughout the region.

Check out other implementations in the field of construction machinery service and diesel engine service.