Renovation of the Liebherr D926 TI-E Engine in the RL 54 Pipe Layer

Engine overhaul Liebherr D926 TI-E in the pipe layer Liebherr RL 54

In our company WIBAKO, we conducted a comprehensive overhaul of the Liebherr D926 TI-E engine with a power of 180 kW, installed in the pipe layer Liebherr RL 54. This machine, being one of the key models in pipeline construction and transmission infrastructure, was designed to operate in challenging terrain conditions. The repair was carried out in the Małopolskie Voivodeship, near Kraków, where our mobile service disassembled the power unit and then transported the engine to our facility in Kojszówka.

The Liebherr D926 TI-E engine is a 6-cylinder diesel unit with a capacity of 10.5 liters, known for its durability and high operational culture. Despite its reliable design, these engines – after many years of operation – require thorough overhauls to restore full efficiency. In this case, the reason for the repair was wear of the cylinders and pistons, manifested by a drop in power and increased oil consumption.

Engine disassembly

The disassembly of the engine from the Liebherr RL 54 pipe layer was performed on-site at the client's location using a crane provided by the investor. Our technicians disconnected all hydraulic, electrical, and mechanical connections, disassembling the accessory components – radiator, intake, exhaust, and fuel system pipes. Each component was carefully labeled and secured for transport. After preparing the unit, the engine was cautiously lowered and loaded onto the WIBAKO service vehicle, then transported to our main workshop in Kojszówka.

Verification of components

The verification began with a complete disassembly of the power unit. During the initial inspection, significant wear of the cylinder liners and excessive play of the pistons were confirmed. A compression measurement was conducted, which showed values below the manufacturer's permissible standards. The crankshaft was also checked – measurements of the main and connecting rod journals indicated the need for regeneration. The cylinder head underwent a leak test in a water bath using compressed air, where leaks were found in two valve seats.

Regeneration and repair

Crankshaft-piston system

As part of the regeneration of the crankshaft-piston system, the crankshaft was ground, and the main and connecting rod bearings were replaced. The cylinder liners were replaced with new ones, and the pistons along with the rings were adjusted to the repair size. The connecting rods were subjected to geometry control and twisting tests.

Engine head

The head underwent a complete regeneration – planing, replacement of guides and valves, as well as a new leak test. Micro-cracks in the valve seats were removed, and the valve stem seals were replaced, restoring proper compression and sealing of the combustion chamber.

Fuel system and accessories

The injection pump was checked on the test bench, and the injectors underwent opening pressure adjustment. Additionally, the turbocharger was verified – control of longitudinal and transverse clearances showed wear, so it was subjected to regeneration. The starter and alternator were also regenerated.

Engine assembly

After completing the repairs and workshop tests, the engine was assembled according to the manufacturer's procedures. The installation in the Liebherr RL 54 pipe layer took place at the machine's work site, in the presence of the operator. Our service technicians installed the engine, replaced the air, cooling, and oil lines, and calibrated the fuel system. Each connection was checked for tightness. Before starting, the oil and fuel filters were replaced, and operating fluids were replenished. After assembly, initial functional tests were performed – starting, checking idle and load RPM, as well as verifying proper cooperation with the hydraulic system. After positive verification, an assembly acceptance protocol was signed.

Engine dynamometer test

Every engine overhauled by WIBAKO, including the Liebherr D926 TI-E, is tested on our modern engine dynamometer. The engine was started under controlled conditions, initially with a load of 25% of nominal for 16 hours. During this time, operational parameters were monitored, including oil pressure, coolant temperature, and exhaust emission levels. After preliminary tests, full load trials were conducted, confirming the correct performance and stability of the unit. Our dynamometer allows for verification of power and torque parameters, which is a key stage in the technical acceptance of the engine. This ensures that the client receives assurance that after installation in the machine, the engine operates according to the manufacturer's standards.

Engine maintenance after overhaul

After handing over the machine for operation, we recommend performing the first inspection after 50 operating hours. At that time, our WIBAKO mobile service conducts filter replacements and checks hydraulic, fuel, and electrical connections. Subsequent inspections are recommended every 250 operating hours or every 3 months. All our repairs are covered by a warranty, and the after-sales service includes advice on the operation of Liebherr engines.

Liebherr D926 TI-E engine - applications

The Liebherr D926 TI-E engines are used not only in Liebherr RL 54 pipe layers but also in R934 series crawler excavators, L564 loaders, self-propelled cranes, and Liebherr special machines. Due to their high durability and efficiency, these units are often used in the mining industry, infrastructure construction, and heavy industry.

Summary

The overhaul of the Liebherr D926 TI-E engine in the Liebherr RL 54 pipe layer was carried out comprehensively – from disassembly, through complete regeneration, dynamometer testing, to installation in the machine and commissioning. Thanks to the experience of our team and technical facilities in Kojszówka, the machine regained full operational efficiency. The client received the engine with a warranty and service support, ensuring the safety of further operation.

If you need repair or overhaul of a Liebherr engine, contact us – we offer comprehensive service for construction machines, including verification and testing on the engine dynamometer.