Renovation of the Liebherr D924 TI-E Engine in the LTM 1200/1 Crane

Liebherr D924 TI-E Engine Overhaul in an LTM 1200/1 All-Terrain Crane

Comprehensive Service of the LTM 1200/1 All-Terrain Crane

The LTM 1200/1 all-terrain crane is one of the most recognizable machines used in assembly, energy, and industrial operations. The machine was designed for heavy-duty work and frequent transportation between construction sites. The unit is powered by a Liebherr D924 TI-E engine with an output of approximately 180 kW, providing the torque characteristics required for crane operation.

A company carrying out infrastructure projects in the Małopolska region near Kraków contacted our service department. Crane operators reported issues related to difficult engine starting, unstable operation under load, and periodic white smoke from the exhaust system. Additionally, coolant loss and increased engine operating temperature were observed.

The Liebherr D924 TI-E engine is a diesel unit used in many construction machines and industrial equipment manufactured by Liebherr. The manufacturer has specialized for many years in both all-terrain cranes and industrial diesel engines designed for operation in demanding conditions. Engines from this series are valued for their durability and ability to operate for extended periods under heavy load.

After preliminary diagnostics, our mobile service team identified probable cylinder head damage caused by engine overheating. A decision was made to remove the engine and carry out a complete inspection in our workshop.

Preliminary Diagnostics of the Liebherr D924 TI-E Engine

Before disassembly, we performed detailed diagnostics of the LTM 1200/1 all-terrain crane directly at the customer’s site. Our mobile service team analyzed engine operating parameters under load and inspected the cooling system.

The machine operator reported a gradual increase in engine operating temperature during intensive crane use. White smoke from the exhaust and periodic power loss were also observed. We first checked the cooling system for leaks, inspected the radiators, and verified proper fan operation.

During diagnostics, a CO2 presence test was carried out in the cooling system. The result indicated the possibility of exhaust gases entering the cooling system. We then performed a pressure test and cylinder compression measurements.

The obtained results confirmed the need for further engine inspection after removal. The customer decided to proceed with a complete engine overhaul together with dynamometer testing.

Engine Removal from the LTM 1200/1 All-Terrain Crane

The removal of the Liebherr D924 TI-E engine was carried out by our mobile service team at a construction site near Kraków. The customer provided a crane enabling the safe extraction of the power unit from the crane chassis.

The process began with disconnecting the batteries and securing the machine’s electrical system. Operating fluids were drained, and the hydraulic, cooling, and fuel system lines were properly secured.

Due to the crane’s design, it was necessary to remove some service covers and intake system components. The mechanics carefully marked all hoses and connections to ensure correct reassembly later.

Special attention was paid to securing the radiators and air lines. In all-terrain cranes, proper routing of installations is crucial for the machine’s future reliability.

After disconnecting the accessories and engine mounts, the engine was lifted out using a crane and prepared for transport to our headquarters in Kojszówka.

Inspection of the Liebherr D924 TI-E Engine

After delivering the engine to the workshop, we began a detailed disassembly and inspection of all components. During cylinder head removal, earlier assumptions regarding engine overheating were confirmed.

Inspection revealed microcracks within the cylinder head and traces of coolant entering the combustion chamber. Signs of piston overheating and excessive thermal load were also visible.

We carried out a complete crankshaft inspection, including journal measurements, oil channel inspection, and runout testing. The crankshaft qualified for reconditioning through grinding.

Connecting rod inspection included twist measurements and checks for overheating damage. All components were thoroughly cleaned and inspected by our mechanics.

The turbocharger and fuel system were also inspected. The injectors were sent to a test bench for detailed diagnostics of operating parameters.

Crankshaft and Piston Assembly Repair

The overhaul of the Liebherr D924 TI-E engine included comprehensive reconditioning of the crankshaft and piston assembly. First, we performed crankshaft grinding followed by dimensional verification after machining.

The engine received new main and connecting rod bearings, a complete set of pistons, piston rings, and cylinder liners. All components were selected according to manufacturer specifications.

The mechanics also thoroughly cleaned the lubrication system and inspected the oil pump. Oil passages were blown through and checked for proper flow.

All seals and consumable components responsible for engine sealing were replaced.

Cylinder Head and Engine Accessories Reconditioning

The damaged cylinder head underwent comprehensive reconditioning. The process included surface machining, replacement of valve guides, valves, and valve stem seals.

After completing the work, a leak test was performed in a heated water bath. The cylinder head was rechecked for possible microcracks.

The turbocharger was also reconditioned. Radial and axial shaft play were checked, and worn rotating assembly components were replaced.

The fuel system was tested on a diagnostic bench. The injectors required adjustment and replacement of consumable parts. This allowed restoration of the proper combustion process.

The alternator and starter motor were disassembled, cleaned, and fitted with new consumable components.

Professional Assembly of the Liebherr D924 TI-E Engine

After reconditioning all components, we began assembling the power unit according to Liebherr service documentation.

Each component was carefully checked for cleanliness and dimensional compliance before installation. Mechanics monitored bolt tightening torques and proper timing settings.

During assembly, rubber hoses, clamps, and worn cooling system components were also replaced. Particular attention was paid to the sealing of the intake and cooling systems.

After assembly, the lubrication system was pre-filled and the engine prepared for its first start on the engine dynamometer.

Liebherr D924 TI-E Engine Testing on the Engine Dynamometer

Every engine rebuilt by our company undergoes mandatory dynamometer testing. This is one of the most important stages of the repair process because it allows verification of the engine before installation in the machine.

The Liebherr D924 TI-E engine was mounted on a test bench equipped with a controlled load system. Before the first startup, we bled the fuel system and checked oil pressure.

The initial operating phase was carried out under light load corresponding to approximately 20–30% of nominal load. This enabled proper seating of the new crankshaft and piston assembly components.

During testing, we monitored operating temperature, oil pressure, exhaust gas temperature, and boost parameters. The dynamometer allows extremely accurate verification of engine behavior under various load conditions.

After the break-in phase, the engine was repeatedly loaded to operating values corresponding to actual all-terrain crane working conditions. We monitored parameter stability and the sealing of all systems.

Our engine dynamometer enables detection of any irregularities before installation in the machine. As a result, the customer receives a tested engine ready for further operation.

After completing the long-duration tests, an oil inspection and another engine leak inspection were performed. All operating parameters complied with manufacturer requirements.

Engine Installation in the LTM 1200/1 Crane

Installation of the rebuilt engine was carried out at the customer’s site by our mobile service team. The process required careful preparation of the engine compartment and inspection of all systems cooperating with the power unit.

After positioning the Liebherr D924 TI-E engine, we connected the cooling, fuel, intake, and electrical systems. The mechanics paid particular attention to the sealing of all connections.

During installation, some hoses and rubber components of the cooling and air intake systems were replaced. This minimized the risk of future leaks.

After completing the installation, we bled the systems and performed the first engine startup in the presence of the crane operator. Multi-hour operational tests covering hydraulic operation and machine driving were then carried out.

After successful completion of the tests, the installation protocol was signed and the crane was handed back to the customer for further operation.

Post-Overhaul Service Support

Every rebuilt engine requires proper service support after overhaul. The customer received recommendations regarding the first operating hours and the inspection schedule.

Our mobile service team will perform the first inspection after 50 operating hours. The scope includes filter replacement, leak inspection, and verification of all connections between the engine and the crane systems.

Subsequent inspections should be carried out every 250 operating hours or at least once every 3 months.

Machines Using the Liebherr D924 TI-E Engine

The Liebherr D924 TI-E engine is used in many construction and industrial machines. The unit is commonly installed in all-terrain cranes, material handling machines, and specialized Liebherr equipment.

WE PROVIDE comprehensive Liebherr engine overhauls, all-terrain crane repairs, and professional engine dynamometer testing services for customers throughout Poland.

Summary of the Liebherr D924 TI-E Engine Overhaul

The comprehensive overhaul of the Liebherr D924 TI-E engine in the LTM 1200/1 all-terrain crane restored the machine to full operational condition and ensured safe future operation.

Thanks to detailed diagnostics, professional component reconditioning, and engine dynamometer testing, the customer received a verified power unit ready for operation under heavy load.

We specialize in services such as construction machinery service, Liebherr engine overhauls, all-terrain crane repairs, and mobile construction equipment service.

Related services:
Liebherr Engine Overhauls
All-Terrain Crane Service
Engine Dynamometer Testing for Industrial Engines
Mobile Construction Equipment Service