Reconstruction of the Liebherr D924 TI-E Engine in the LTM 1220 (NX) Crane

Engine overhaul of Liebherr D924 TI-E in the LTM 1220 (NX) mobile crane

The mobile crane Liebherr LTM 1220 (NX) is an advanced engineering design used on construction sites, in industry, and for the assembly of steel structures. It is powered by a reliable Liebherr D924 TI-E engine with a power output of approximately 180 kW, known for its high durability and efficiency. A unit was brought to our service where the user reported a decrease in power and an increase in oil consumption. After initial diagnostics, it was determined that a complete overhaul of the power unit was necessary.

The manufacturer Liebherr is renowned for producing top-class heavy construction machinery, and its engines – such as the D924 TI-E – are designed for long-term operation in harsh conditions. At our service WIBAKO, we specialize in comprehensive regeneration of engines of this brand, using an engine test bench for load testing before installation in the machine.

Engine disassembly

The disassembly of the Liebherr D924 TI-E engine was carried out in the field, near Katowice, by our mobile service WIBAKO. Using a crane provided by the client, the unit was removed from the frame of the mobile crane. All fuel, cooling, and electrical lines were properly secured. After disassembly, the engine was transported to our headquarters in Kojszówka, where the detailed verification process began.

Verification of components

During the initial diagnostics, excessive wear of the cylinders and pistons was found, resulting in a drop in compression and increased oil consumption. Compression pressure measurements and endoscopy of the cylinders confirmed the wear of the liner surfaces. After disassembling the engine, the condition of the crankshaft, connecting rods, bearings, cylinder head, and fuel system was analyzed. Micrometric measurements and a leak test of the cylinder head were performed using a water bath with a pressure test. The results indicated the need for a complete regeneration of the crank-piston system and the cylinder head.

Regeneration and repair

The Liebherr D924 TI-E engine underwent a comprehensive regeneration process. The cylinder liners were replaced, and the pistons and rings were matched to the new nominal dimensions. The crankshaft was ground and balanced, and new bearings were installed according to the manufacturer's tolerances. The cylinder head was planed, received new valves and valve guides. The fuel system underwent verification of the injection pump and injectors on the test bench. The turbocharger and engine accessories (alternator, starter) were also regenerated. All components were thoroughly cleaned and prepared for assembly.

Engine assembly

After regeneration, the engine was reassembled following all service standards. New gaskets, fuel lines, cooling, and air lines were installed. Special attention was paid to the tightness of connections and the precision of tightening moments. After assembly, a test run was performed in the workshop, and then testing on the engine test bench commenced.

Testing on the engine test bench

All engines after repair at WIBAKO are tested on our professional engine test bench. The tests last at least 16 hours and include both light and full loads to verify the operating parameters of the power unit. For the Liebherr D924 TI-E engine, oil pressure, temperature, fuel consumption, and power parameters were monitored. After the tests, the engine met all manufacturer requirements, which was confirmed by a measurement protocol. Thanks to the test bench, we ensure that every engine leaving our workshop is fully operational and ready for use.

Installation in the machine

After successful tests, the engine was reinstalled in the LTM 1220 (NX) crane. The installation was carried out at the client's site in the presence of the machine operator. Our technicians conducted a comprehensive connection of the fuel, air, and electrical systems, as well as a leak test of all connections. A trial run and load tests of the crane were performed. After verifying the parameters and ensuring there were no leaks, an installation protocol was signed. The machine was restored to full operational capacity, and the client received detailed recommendations for post-repair maintenance.

Engine maintenance after repair

Every engine after repair at WIBAKO is covered by a warranty. We recommend performing the first inspection after 50 operating hours, which includes changing filters and checking connections. Subsequent inspections should be conducted every 250 operating hours or every 3 months. Our mobile service can reach the machine's work site to carry out necessary maintenance tasks. Regular maintenance and monitoring of engine operating parameters help maintain its high reliability and extend its lifespan.

Liebherr D924 TI-E engines - applications

The Liebherr D924 TI-E engine, with a power output of approximately 180 kW, is widely used in Liebherr machines – primarily in mobile cranes, wheeled loaders, and specialized machines. Thanks to its design, it provides optimal performance with low fuel consumption and high operational culture.

Summary

The overhaul of the Liebherr D924 TI-E engine in the LTM 1220 (NX) mobile crane was carried out comprehensively, in accordance with the manufacturer's standards and confirmed by tests on the test bench. As a result, the machine regained full power and operational efficiency. The client gained assurance of the crane's reliable operation in challenging terrain conditions. The WIBAKO team guarantees the highest quality of services in diesel engine service for Liebherr and professional technical support throughout the country.