Liebherr D934 A7 SCR D936 A7 SCR D946 A7 SCR Diesel Engine Operating Manual 10140787-00 – PDF

LIEBHERR Diesel engine D934 A7 SCR - D936 A7 SCR - D946 A7 SCR BAL: 10140787-00-en

Operating manual

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en Dieselmotor D934 A7 D936 A7 D946 A7- SCR featuring exhaust gas after-treatment system SCR (selective catalytic reduction) From serial number 2012030001 / 2012040001

Document ID Order number: Issued: Version: Author:

10140787 01.01.2012 00 LMB / Department BE-MD3

Product ID Manufacturer: Type: Type no.: Serial no. from:

LIEBHERR MACHINES BULLE S.A. D934 A7 D936 A7 D946 A7 SCR featuring exhaust gas after-treatment system SCR (selective catalytic reduction) 2012030001 / 2012040001

Contact Address:

LIEBHERR MACHINES BULLE S.A. 45, rue de l'Industrie CH-1630 BULLE SCHWEIZ

Machine data: Enter the following information on taking delivery. *You will find the information on the type plate of the machine. This will also be useful when you order spares.

* Engine ID number: ............................................................

* Year of construction: .............................

Commissioning date:

LMB/10140787/00/01.01.2012/en

.................. / ................. / .................

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D934 A7 D936 A7 D946 A7 SCR featuring exhaust gas after-treatment system SCR (selective catalytic reduction) / 2012030001 / 2012040001

Foreword

These operating instructions have been compiled for the user and for the maintenance personnel of the diesel engine.

The instructions include descriptions regarding: – Technical data – Safety requirements – Operation and servicing – Maintenance The operating manual is to be read thoroughly and referred to before initial start-up and at regular periods thereafter by each person contracted to carry out work with/on the diesel engine.

Tasks with or on the diesel engine include for example: – Operation, servicing, disposing of fuels and lubricants.

– Repair, including maintenance and inspection.

This simplifies training of the operator for his diesel engine and prevents malfunctions resulted from improper use.

Please understand that we do not recognise warranty claims submitted as a result of improper operation, insufficient maintenance, the utilisation of impermissible fuels or negligence of the safety guidelines.

LIEBHERR will declare all possible undertakings carried out by LIEBHERR and/or their dealers, such as guarantees, service orders, etc. null and void without advance notice, if spare parts other than original LIEBHERR spare parts or spare parts purchased by LIEBHERR are used for maintenance or repair.

It may be necessary to undertake maintenance tasks more regularly than is prescribed in the inspection plan when working in tougher conditions.

LMB/10140787/00/01.01.2012/en

Modifications, conditions and copyright: – Modifications of technical data, as regards information and illustrations within the documentation currently valid for the diesel engine, remain reserved.

– Conditions for warranty and liability of the general terms of trade for the LIEBHERR Company are not extended by the aforementioned details.

– Information and diagrams featured within this operating manual may not be reproduced or distributed, nor used for the purpose of the competition. All rights remain exclusively reserved in accordance with copyright laws.

D934 A7 D936 A7 D946 A7 SCR featuring exhaust gas after-treatment system SCR (selective catalytic reduction) / 2012030001 / 2012040001

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LMB/10140787/00/01.01.2012/en

Foreword

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D934 A7 D936 A7 D946 A7 SCR featuring exhaust gas after-treatment system SCR (selective catalytic reduction) / 2012030001 / 2012040001

Contents

1

Product description

9

1.1

Technical description

9

1.1.1

Overview of assembly

9

1.1.2

Explanation of type description

11

1.1.3

Design features

14

1.1.4

Special equipment for the diesel engine

16

1.2

LMB/10140787/00/01.01.2012/en

2

Technical data

17

1.2.1

Diesel engine

17

1.2.2

Cylinder head, standard

17

1.2.3

Cylinder head with engine auxiliary brake system (ZBS)

18

1.2.4

Coolant pump D934

18

1.2.5

Coolant pump D936 / D946

18

1.2.6

Coolant thermostat

18

1.2.7

Generator

18

1.2.8

Starter

18

1.2.9

Flywheel housing

19

1.2.10 Air compressor Wabco 293 cm3

19

1.2.11 Air compressor Wabco 352 cm3

19

1.2.12 Air compressor Knorr 300 cm3

19

Notes on safety

21

2.1.1

21

Designation of warning information

2.2

General notes on safety

22

2.3

Use as directed

22

2.4

Notes on the prevention of crushing and burns

23

2.5

Notes on the prevention of fire and explosions

23

2.6

Observe safety precautions when starting

23

2.7

Measures for safe maintenance

24

2.8

Observe the safety precautions for diesel engines featuring electronic control units

25

D934 A7 D936 A7 D946 A7 SCR featuring exhaust gas after-treatment system SCR (selective catalytic reduction) / 2012030001 / 2012040001

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Contents

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4

5

Safety and emergency run program for diesel engines featuring electronic control units

2.10 Special notes regarding tasks on the Common Rail System

26

2.11 Particularly hazardous

27

2.12 Disposing of fuels and lubricants

29

2.13 Exhaust gas after-treatment system (SCR)

29

Operation, Servicing

31

3.1

Control and operating elements

31

3.2

Operation

32

3.2.1

Preparations prior to initial start-up

32

3.2.2

Initial start-up / test run

32

3.2.3

Start the diesel engine.

33

3.2.4

Starting in frosty temperatures

34

3.2.5

Switching off the diesel engine.

34

3.2.6

Exhaust gas after-treatment system (SCR)

35

Malfunctions

45

4.1

45

Faults - Cause - Remedy

Maintenance

51

5.1

Maintenance and inspection chart

51

5.2

Filling amounts

54

5.2.1

54

5.3

Table for filling amounts

Fuels and lubricants

55

5.3.1

Handling fuels and lubricants

55

5.3.2

Environmental-protection guidelines

55

5.3.3

Disposing of used materials

55

5.3.4

Diesel fuels

55

5.3.5

Lube-oils for the diesel engine

56

5.3.6

Coolant for diesel engine

58

5.4

Special tools for maintenance tasks

62

5.5

Preparatory maintenance tasks

65

5.6

Maintenance tasks (daily), every 10 operating hours

66

5.6.1

Check the engine oil level

66

5.6.2

Visual inspection (leaks, contamination, damages)

67

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D934 A7 D936 A7 D946 A7 SCR featuring exhaust gas after-treatment system SCR (selective catalytic reduction) / 2012030001 / 2012040001

LMB/10140787/00/01.01.2012/en

2.9

Contents

5.7

5.8

5.6.3

Check the coolant level

67

5.6.4

Checking / draining the water separator of the fuel prefilter

67

5.6.5

Check low-pressure display of the air filter

69

Maintenance tasks (weekly) every 50 operating hours

70

5.7.1

Drain water and sediment in the fuel tank

70

5.7.2

Cleaning the dust-discharge valve of the air filter

70

Maintenance tasks, every 500 operating hours

71

5.8.1

Check the flap of the diesel engine brake

71

5.8.2

Changing diesel engine oil and replacing the oil filter

71

5.8.3

Replacing the oil separator filter element

75

5.8.4

Checking and replacing the ribbed V-belt

76

5.8.5

Checking induction and exhaust gas system for sound condition and for leaks

78

Check the cooling and heating systems for sound condition and for leaks

78

Checking lubrication system and fuel system for leaks and for sound condition

79

5.8.8

Checking the batteries and cable connections

79

5.8.9

Checking the control unit mounting for sound condition

79

5.8.10 Checking sensors, actuators, cable fittings and plugs for sound condition

80

Maintenance tasks every 1000 operating hours

81

5.8.6 5.8.7

5.9

5.9.1

Checking the oil sump, engine mount and diesel engine brackets for secure seating

81

5.9.2

Checking and adjusting valve clearance

82

5.9.3

Replacing the fuel prefilter element

87

5.9.4

Replacing the fuel fine-filter

88

5.10 Maintenance tasks every 2000 operating hours 5.10.1 Checking anticorrosive / antifreeze concentration in the coolant

LMB/10140787/00/01.01.2012/en

5.11 Maintenance tasks every 3000 operating hours

90 90 94

5.11.1 Grease the flywheel starter ring gear

94

5.11.2 Replacing the coolant

94

5.12 Maintenance tasks every 4500 operating hours 5.12.1 Replacing the foam element and the filter element of the SCR urea pump 5.13 Maintenance tasks every 10000 operating hours 5.13.1 Replace the heater flange

D934 A7 D936 A7 D946 A7 SCR featuring exhaust gas after-treatment system SCR (selective catalytic reduction) / 2012030001 / 2012040001

97 97 99 99

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5.14 Maintenance tasks as required

100

5.15 Check the heater flange

101

5.16 Bleeding the fuel system

102

5.17 Replacing the dry air filter main element

106

5.18 Replacing the dry air filter safety element

107

5.19 Transport and storage

108

5.19.1 Lifting gear

108

5.19.2 Storage up to 6 months

108

5.19.3 Storage for between 6 and 24 months

109

Supplemental Information USA 6.2.1 6.3

111

EPA/CARB Fuel label

111

Emission control warranty statement warranty rights and obligations

112

6.3.1

Manufacturer's warranty coverage

112

6.3.2

Owner's warranty responsibilities

112

6.3.3

Warranty coverage

113

6.3.4

Warranted parts

113

Index

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D934 A7 D936 A7 D946 A7 SCR featuring exhaust gas after-treatment system SCR (selective catalytic reduction) / 2012030001 / 2012040001

1 Product description

1.1 Technical description 1.1.1 Overview of assembly

LMB/10140787/00/01.01.2012/en

This section features a summary of the diesel engine including a description of the components represented.

D934 A7 D936 A7 D946 A7 SCR featuring exhaust gas after-treatment system SCR (selective catalytic reduction) / 2012030001 / 2012040001

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Product description Technical description

1 2 3 4 5 6

Visco-damper Water pump Automatic tension pulley Thermostat housing Throttle valve Heater flange

7 8 9 10 11 12

Cylinder head cover Air induction pipe Connecting line Intake manifold Starter Exhaust turbocharger

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13 14 15 16

Crankcase Oil sump Exhaust pipe Oil cooler

D934 A7 D936 A7 D946 A7 SCR featuring exhaust gas after-treatment system SCR (selective catalytic reduction) / 2012030001 / 2012040001

LMB/10140787/00/01.01.2012/en

Fig. 1: Components of diesel engine D936 A7 SCR / view from the left

Product description Technical description

LMB/10140787/00/01.01.2012/en

Fig. 2: Components of the diesel engine D936 A7 SCR / view from the right 1 2 3 4 5 6

Flywheel Flywheel housing Power take-off NA1 Power take-off NA2 Intake manifold Connecting line

7 8 9 10 11 12

Crankcase breather Fuel fine filter Oil filter Air-conditioning compressor Engine control unit Generator

13 14 15 16 17

Power take-off NA4 Oil intake Oil dipstick Power take-off NA3 SCR-Box

1.1.2 Explanation of type description Engine classification Description D

93

6

A7

SCR

D D934 A7 D936 A7 D946 A7 SCR featuring exhaust gas after-treatment system SCR (selective catalytic reduction) / 2012030001 / 2012040001

Engine type description Engine type: D = Diesel engine

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DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL