Engine Overhaul of D924 TI-E in LTM 1250/1 Crane

D924 TI-E Engine Overhaul in LTM 1250/1 Mobile Crane

The LTM 1250/1 mobile crane is an advanced machine from Liebherr, valued for its stability and lifting capacity in challenging construction conditions. Equipped with a D924 TI-E engine with a power output of approximately 180 kW, it ensures not only high performance but also reliability when lifting and transporting heavy loads. The D924 TI-E engine, manufactured by Liebherr, is a diesel unit characterized by a robust design and long service life, making it ideal for crane applications.

In the case of this particular unit, our team's mobile service conducted comprehensive diagnostics and an engine overhaul near Katowice. The repair was necessitated by symptoms typical of natural engine wear: gradual loss of power, increased fuel consumption, and higher oil consumption. Thanks to specialized tools and experience, our mobile service performed full diagnostics both on-site and at our headquarters in Kojszówka.

Stages of Work for the LTM 1250/1 Engine Overhaul

Engine Disassembly

The process began with the disassembly of the engine using a crane provided by the client. Mechanics secured all cooling system components, the air intake, and fuel lines. Subsequently, the engine mounts were unscrewed, and the unit was precisely removed, preparing it for transport to our workshop. At this stage, preliminary leak tests were performed, and the condition of the accessories was visually inspected, allowing us to determine the further scope of work.

Component Verification

The D924 TI-E engine underwent detailed verification. The crank-piston system, crankshaft, connecting rods, and pistons were checked for wear and potential damage. The cylinder head was subjected to a pressure test and a visual inspection of the valve seats. Additionally, the turbocharger, injection pump, and other mechanical and electro-mechanical accessories were checked. Oil analysis allowed us to rule out contamination in the lubrication system as the cause of the drop in performance parameters.

Regeneration and Repair

The repair process involved comprehensive actions in several areas:

Engine Installation

After the regeneration was completed, the engine was precisely installed in the LTM 1250/1 crane. The installation process included reconnecting all fuel lines, the cooling system, and the air intake, replacing piping and filters, and conducting preliminary connection leak tests. Mechanics performed thorough functional tests with the participation of the machine operator, monitoring engine performance parameters, startup correctness, and the control system's response. The assembly concluded with the preparation of an acceptance protocol and a preliminary machine startup in the presence of the client.

Engine Dynamometer Test

After assembly, the D924 TI-E engine underwent an intensive test on an engine dynamometer. The testing included an initial run at minimum load (20-30% of nominal power) for 16 operating hours to monitor operation correctness, followed by a gradual increase in load. Our dynamometer allows for precise simulation of crane operating conditions, enabling the detection of any irregularities before the machine is returned to the client. The test confirmed the full functionality of the unit and the correctness of all engine operating parameters.

Post-Overhaul Engine Maintenance

Following the overhaul, the D924 TI-E engine is covered by a full warranty. We recommend a service inspection after 50 operating hours, which includes filter replacement and an inspection of the overall condition of the engine and accessories. Subsequent inspections should be performed every 250 operating hours, but no less frequently than every 3 months, to maintain the unit in optimal working condition.

Information on Machines Using This Engine

The D924 TI-E engine is used in Liebherr LTM series mobile cranes, guaranteeing reliability, high power, and durability in demanding construction conditions. Our knowledge and experience in servicing these units allow us to ensure full machine efficiency and the safety of heavy load lifting operations.