Liebherr Diesel engine D934 A7–04 D944 A7–04 D936 A7–04 D946 A7–04 Operation Maintenance Manual

en

Operator's manual Diesel engine D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 From serial number 2014030001 / 2014040001

Document ID Order number: Issued: Version: Author:

10154726 04.07.2018 04 LMB / Department DC2

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

LIEBHERR MACHINES BULLE S.A. D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 2014030001 / 2014040001

Contact Address:

Liebherr Machines Bulle SA 45, rue de l'Industrie CH-1630 BULLE SWITZERLAND

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 manufacture: .............................

Commissioning date:

LMB/10154726/04/04.07.2018/en

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

copyright © Liebherr Machines Bulle SA 04.0

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

Preface

About the document Content The descriptions for maintenance and care of the engine can be found in these operating instructions.

Work instructions A prerequisite for proper maintenance is a proper and complete basic tool, as well as the required devices and special tools.

Use only clean and undamaged tools. Damaged tools must not be re-used; they must be replaced in good time. Cleanliness and order contribute to safety at the workplace.

Clean the diesel engine and, here in particular, the connections and screw fittings of oil, fuel and care products at the start of the repair work. Do not use aggressive cleaning agents. Use lint-free cleaning rags. Do not use any flammable liquids to clean the diesel engine.

Sealing materials (e.g. o-rings, seals etc.) are to be replaced.

Parts that are removed are to be checked for reusability and replaced if necessary.

Screw connections are to be tightened according to the standard torques if no specific torque and tensioning instructions are stated.

Spare parts Only original LIEBHERR spare parts or spare parts purchased from LIEBHERR may be used for the maintenance of LIEBHERR diesel engines.

LMB/10154726/04/04.07.2018/en

LIEBHERR will cancel all possible obligations received by LIEBHERR and/or its dealers, such as guarantees, service contracts etc., without advance notice if any parts other than original LIEBHERR parts or spare parts purchased from LIEBHERR are used for maintenance.

All "Part information" in these operating instructions, e.g. ID numbers, thread dimensions, dimensions, etc. are for information only; spare parts may only be ordered using the spare parts catalogue that is part of the scope of delivery.

Lubricants and operating fluids Only lubricants and operating fluids that are approved by LIEBHERR may be used to operate LIEBHERR diesel engines.

LIEBHERR will cancel all possible obligations received by LIEBHERR and/or its dealers, such as guarantees, service contracts etc., without advance notice if any lubricants or operating fluids other than those approved by LIEBHERR are used.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

copyright © Liebherr Machines Bulle SA 04.0

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Preface

Operator's manual

Usage instructions Certain illustrations in these operating instructions may depict details that differ from your diesel engine. The relevant work must then be carried out in accordance with the work description provided.

Improvements that have been made to the diesel engines may result in changes that are not mentioned in these operating instructions.

If you require further explanations or information, contact the LIEBHERR customer service and customer service school departments. There is no update service for the operating instructions. The operating instructions are revised according to the technical requirements and their current version is then published.

The service information issued by Liebherr Machines Bulle is a supplement to the operating instructions after a version of them is published.

Graphic icons in this manual Icon

Meaning Note Identifies useful information and tips.

Prerequisite Identifies conditions for subsequent action steps.

Call to action Identifies action steps.

Result Identifies results of one or more action steps.

List Identifies individual points of a list.

Icons

Changes, conditions, copyright:

ISO 16016 protection notice: “The reproduction, distribution and utilization of this document as well as the communication of its contents to others without express authorisation is prohibited. Infringements will incur an obligation to pay compensation for damages. All rights reserved for registering patents, utility models or designs.”

copyright © Liebherr Machines Bulle SA 04.0

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

LMB/10154726/04/04.07.2018/en

We reserve the right to make changes to this document in the interest of technical improvement.

Contents

1

Product description

9

1.1

Technical description

9

1.1.1

Design overview

9

1.1.2

Explanation of type designation

10

1.2

2

Technical data

14

1.2.1

Diesel engine

14

1.2.2

Standard cylinder head

14

1.2.3

Cylinder head with engine auxiliary brake system (ABS)

14

1.2.4

Coolant thermostat

15

1.2.5

Alternator

15

1.2.6

Starter

15

1.2.7

Flywheel housing

15

Safety instructions 2.1.1 2.2

Identification of the warnings

17 17

Target group

18

2.2.1

18

Unauthorised personnel

Intended use

18

2.4

Limitation of liability

19

2.5

General safety instructions

19

2.6

Preventing personal injuries

20

2.6.1

Crushing

20

2.6.2

Burns and scalds

20

2.6.3

Fires and explosions

21

2.6.4

Poisoning

21

2.6.5

High-pressure injection (fluids spraying out under high pressure)

21

2.6.6

Electrical energy

21

2.6.7

Danger due to noise

22

LMB/10154726/04/04.07.2018/en

2.3

2.7

Personal protective equipment

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

22

copyright © Liebherr Machines Bulle SA 04.0

5

Operator's manual

2.8

2.9

3

5

23

2.8.1

Safety instructions

23

2.8.2

Operating areas

23

2.8.3

Maintenance areas

24

2.8.4

Securing and releasing the diesel engine against unexpected start-up

25

2.8.5

Emergency stop

25

2.8.6

Signage

25

Preventing property damage

26

2.10 Disposal of operating fluids

27

2.11 Exhaust after-treatment system (SCR)

28

Operation

29

3.1

Indicator and warning lamps

29

3.2

Starting the engine

35

3.2.1

Preceding work for the initial commissioning of the engine

35

3.2.2

Starting the engine

35

3.2.3

Shutting off the engine

37

Exhaust after-treatment system

38

3.3.1

38

3.3

4

Operating areas and maintenance areas

Handling / use of NOX reducing agent

Operating faults

41

4.1

41

Faults - Cause - Remedy

Maintenance

47

5.1

Maintenance and inspection schedule

47

5.2

Fill quantities

50

5.2.1

50

5.3

Lubricants and operating fluids

Lubricants and operating fluids

51

5.3.1

Diesel fuels

51

5.3.2

Reducing agent

51

5.3.3

Engine oils

51

5.3.4

Coolant

53

5.4

Special tools for maintenance activities

54

5.5

Preparatory maintenance activities

57

5.6

Maintenance activities (daily) every 10 operating hours

58

copyright © Liebherr Machines Bulle SA 04.0

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

LMB/10154726/04/04.07.2018/en

Contents

Operator's manual

Contents

5.7

5.8

5.9

5.6.1

Checking the engine oil level

58

5.6.2

Visual inspection (leaks, contaminations, damage)

58

5.6.3

Checking the coolant level

59

5.6.4

Checking / draining water trap on the fuel prefilter

59

5.6.5

Checking the underpressure display of the air filter

61

5.6.6

Visual inspection of exhaust after-treatment system

61

Maintenance activities every 50 operating hours (weekly)

62

5.7.1

Draining water and sediments from the fuel tank

62

5.7.2

Clean the dust extraction valve of the air filter

62

5.7.3

Inspecting the exhaust after-treatment system profile clips

62

Maintenance activities every 500 operating hours

64

5.8.1

Checking state of belt drive and replacing, if necessary

64

5.8.2

Checking the intake and exhaust system for condition and leaks

64

5.8.3

Check cooling and heating system for condition and leaks

65

5.8.4

Checking the lubricant and fuel system for condition and leaks

65

5.8.5

Checking the batteries and cable connections

65

5.8.6

Check condition of control unit bearings

65

5.8.7

Check condition of sensors, actuators, cable holders and plugs

66

Maintenance activities every 1000 operating hours

LMB/10154726/04/04.07.2018/en

5.9.1

67

Checking that engine bearing and diesel engine console are securely seated

67

5.9.2

Changing the fuel prefilter insert

67

5.9.3

Changing the fuel fine filter

68

5.10 Maintenance activities every 1500 operating hours

71

5.10.1 Changing the diesel engine oil and oil filter

71

5.10.2 Replacing the oil separator filter insert

74

5.10.3 Checking and setting the valve clearance

76

5.11 Maintenance activities every 2000 operating hours

81

5.11.1 Checking the corrosion frost protection agent concentration in the coolant 5.12 Maintenance activities every 5000 operating hours 5.12.1 Replacing the belt drive 5.13 Maintenance activities every 6000 operating hours 5.13.1 Replacing the coolant 5.14 Maintenance activities every 10000 operating hours 5.14.1 Replacing the heating flange D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

81 83 83 85 85 88 88

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Contents

Operator's manual

6

5.15 Occasional maintenance activities

89

5.16 Checking the heating flange

90

5.17 Venting the fuel system

91

5.18 Replacing the dry air filter main element

93

5.19 Replacing the dry air filter safety element

94

5.20 Transport and storage

95

5.20.1 Suspension device

95

5.20.2 Storage up to 6 months

97

5.20.3 Storage over 6 months up to 24 months

97

Supplemental information for the USA 6.2.1

EPA/CARB fuel label

Index

99 99

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101

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

1 Product description

1.1 Technical description 1.1.1 Design overview

LMB/10154726/04/04.07.2018/en

This section contains an overview of the diesel engine with the names of the parts shown.

Fig. 1: Parts of the diesel engine D936 A7–04 / view from the left 1 2 3 4

Viscous damper Oil cooler Tensioning roller Alternator

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

5 6 7 8

Heating flange Oil filter Water collecting line Cylinder head

9 10 11 12

Exhaust manifold Exhaust turbocharger Exhaust pipe Actuator

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Product description

Operator's manual

Technical description

Fig. 2: Parts of the diesel engine D936 A7–04 / view from the right 1 2 3 4

Flywheel Auxiliary output 1 Transport device Air compressor

5 6 7 8

Crankcase ventilation Fuel fine filter Air intake pipe Engine control unit

9 10 11

Oil dipstick Alternator Oil pan

1.1.2 Explanation of type designation Type designation

D

93

6

A7

04

D

Engine type designation Engine type: D = diesel engine

93

Bore: 93 = 122 mm (94 = 130 mm) / stroke: 150 mm 6

Number of cylinders A7

Injection system: A7 = Common Rail 04

Exhaust after-treatment system: SCR (selective catalytic reduction)

copyright © Liebherr Machines Bulle SA 04.0

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

LMB/10154726/04/04.07.2018/en

Description

Operator's manual

Product description Technical description

Description D

93

6

A7

04

Engine type designation

00

Diesel engines without emission type approval (without exhaust after-treatment system)

Tab. 1

Diesel engine type plate The diesel engine type plate is attached on the right side of the crankcase as seen from the flywheel. There is a second type plate on the air intake pipe.

Fig. 3: Type plate 1 2

Manufacturer US type approval information

7 8

Capacity Engine serial number

13 14

3 4 5

Engine power at rated speed Identification number Engine variant (Liebherr internal type) Engine type

9 10 11

Date of manufacture US performance category EU exemption

15 16 17

12

Fuel minimum requirements

18

LMB/10154726/04/04.07.2018/en

6

EU type approval information ECE type approval information Chinese engine family Chinese emission limit stage Chinese type approval number Liebherr

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

copyright © Liebherr Machines Bulle SA 04.0

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Product description

Operator's manual

Technical description

Engine control unit type plate

Fig. 4: Example of a engine control unit type plate 1 2 3 4 5

Delivery date 2D barcode Engine type Control unit description Engine ID no.

Note

6 7 8 9 10

Engine serial number Control unit ID number Revision index Software version Control unit serial number

The information on the Engine control unit type plate corresponds to the delivery status (ex works Liebherr Machines Bulle). Depending on software updates in the field, it may be the case that this information is no longer up to date. The real information can be viewed in the device display or read out with Liebherr diagnosis.

LMB/10154726/04/04.07.2018/en

Tab. 2

copyright © Liebherr Machines Bulle SA 04.0

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

Operator's manual

Product description Technical description

Cylinder designation, direction of rotation

Fig. 6: Cylinder designation / direction of rotation A = Outlet valve E = Inlet valve

LMB/10154726/04/04.07.2018/en

Cylinder 1 is on the flywheel side. The cylinder numbers and also the firing order are moulded onto the right upper side of the crankcase as seen from the flywheel.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

copyright © Liebherr Machines Bulle SA 04.0

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Product description

Operator's manual

Technical data

1.2 Technical data 1.2.1 Diesel engine Description

Unit Value

Design

Inline diesel engine

Number of cylinders (D934 / D944)

4

Ignition sequence

1-3-4-2

Number of cylinders (D936 / D946)

6

Ignition sequence

1–5–3–6–2–4

Hole (D934 / D936)

mm 122

Hole (D944 / D946)

mm 130

Stroke

mm 150

Displaced volume (D934)

l 7.0

Displaced volume (D936)

l 10.5

Displaced volume (D944)

l 8

Displaced volume (D946)

l 11.95

Compression ratio

17.4:1

Direction of rotation of the diesel engine (seen from flywheel)

left

Power group

LG1 to LG5

Power specification as per

See type plate

Rated power

See type plate

Rated speed

See type plate

Emission limits (A7-04 engines)

Stage IV / Tier 4

Description

Unit Value

Inlet valve clearance, cold

mm 0.3

Outlet valve clearance, cold

mm 0.4

1.2.3 Cylinder head with engine auxiliary brake system (ABS) Description

Unit Value

Inlet valve clearance, cold

mm 0.3

Outlet valve bridge / rocker arm valve clearance, cold

mm 0.6

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

LMB/10154726/04/04.07.2018/en

1.2.2 Standard cylinder head

Operator's manual

Product description Technical data

Description

Unit Value

Outlet valve bridge / counterholder valve clearance, cold

mm 0.4

1.2.4 Coolant thermostat Description

Unit Value

Opening start

°C 82

Completely open

°C 92

1.2.5 Alternator Description

Unit Value

Voltage

V 28

Current, type 1

A 140

Current, type 2

A 180

1.2.6 Starter Description

Unit Value

Voltage

V 24

Capacity

kW 7.8

1.2.7 Flywheel housing Description

SAE 1 / SAE 2

LMB/10154726/04/04.07.2018/en

Connection

Unit Value

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

copyright © Liebherr Machines Bulle SA 04.0

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Product description

Operator's manual

LMB/10154726/04/04.07.2018/en

Technical data

copyright © Liebherr Machines Bulle SA 04.0

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

2 Safety instructions

Working on the diesel engine involves dangers to life and limb that you can encounter as the operating company, machine operator or maintenance specialist.

If you carefully read and follow the various safety instructions time and again, you can prevent dangers and accidents.

This applies in particular to personnel who only occasionally work on the diesel engine during maintenance.

Safety regulations are listed below, the conscientious observance of which ensures your safety and the safety of other persons and prevents damage to the diesel engine.

The required safety precautions are described in the description of work in this manual which could cause dangers to persons or the diesel engine.

2.1.1 Identification of the warnings This is the warning sign. It warns of possible risk of injury. Comply with all measures that are identified with these warning signs in order to avoid injuries or death.

Tab. 3

LMB/10154726/04/04.07.2018/en

The warning sign always appears in connection with the signal words DANGER WARNING CAUTION DANGER

Identifies an immediately dangerous situation that will result in death or serious bodily injuries if it is not prevented.

WARNING

Identifies a dangerous situation that could result in death or serious bodily injuries if it is not prevented.

CAUTION

Identifies a dangerous situation that could result in minor or moderate bodily injuries if it is not prevented.

ATTENTION

Identifies a dangerous situation that could result in property damage if it is not prevented.

Tab. 4

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

copyright © Liebherr Machines Bulle SA 04.0

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Safety instructions

Operator's manual

Intended use

Additional identifications Note

Identifies useful information and tips.

Tab. 5

2.2 Target group 2.2.1 Unauthorised personnel These operating instructions have been written for the operator and for the maintenance personnel of the diesel engine.

All other persons, including operators, supervisors and trainees, are classified as "unauthorised personnel" for maintenance tasks.

They are not permitted to maintain the engine or to access the engine compartment or the engine cover.

2.3 Intended use – Use the diesel engine for the corresponding purpose.

– Adhere to the following conditions from the manufacturer: • Operating conditions • Maintenance conditions • Repair conditions – Make sure that the following activities are only performed by persons according to the target group definition.

• Use the diesel engine.

• Maintain the diesel engine.

• Repair the diesel engine.

– Install guards and protective equipment before commissioning and ensure function.

– Observe the safety instructions and the operating instructions.

– Operate the engine in perfect condition.

– Operate the engine in the speed range prescribed by the manufacturer.

– Bolt engine with attached engine mounts and the corresponding tensioning instructions to the machine or the respective operation site.

– Have engine mounts and engine bearings, which are not installed by the manufacturer, approved by the manufacturer.

– Only operate the engine in areas that are inaccessible to the public; so only operate the engine in connection with an enclosure or engine compartment cover.

copyright © Liebherr Machines Bulle SA 04.0

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

LMB/10154726/04/04.07.2018/en

For more information, see the chapter “Target group”.

Operator's manual

Safety instructions General safety instructions

2.4 Limitation of liability The operating instructions were created according to applicable standards and regulations, in accordance with the state of the art.

Liebherr does not accept any liability for: – Disregarding the instructions – Improper use – Use of personnel that does not meet the requirements according to the target group.

– Changes and conversions to the diesel engine that have been carried out without approval from Liebherr.

– Operating fluids and auxiliary materials that have not been approved by Liebherr.

– Use of non-Liebherr spare parts which have not been approved by Liebherr, including any consequential damages resulting from this.

– Circumventing and failing to comply with safety regulations – Disregarding international and national regulations for occupational safety – Disregarding international and national regulations for environmental protection – Unauthorised changes to the diesel engine – Manipulation on the injection system and control system – Short-term operation of the diesel engine in emergency operation without impairing safety.

Emergency operation with limited safety function is deemed improper use.

Manufacturer cannot be made liable for damages due to improper use.

EU type approval expires for: – Manipulation on the diesel engine – Manipulation on the injection system and control system – Manipulation on the exhaust after-treatment system The actual scope of delivery can differ from these operating instructions due to situational adaptations to customer requirements.

LMB/10154726/04/04.07.2018/en

2.5 General safety instructions – Meet the requirements of the target groups for the work. See “Target group” chapter.

– To ensure assistance in the event of an accident: Second person is present or make sure that the emergency situation is identified and assistance occurs.

– Before maintenance activities, ensure that the personnel is familiar with the operating instructions.

– Only allow the following personnel to work on the diesel engine under the constant supervision of an experienced person: • Personnel being trained • Personnel being instructed • Personnel present for general educational purposes • Apprentices For more information, see the chapter “Target group”.

– Check that personnel are working in a manner that is conscious of safety and hazards under the following conditions: • Observe accident prevention regulations.

• Observe generally accepted safety and health rules.

• Observe the operating instructions.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

copyright © Liebherr Machines Bulle SA 04.0

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Safety instructions

Operator's manual

Preventing personal injuries

– Make sure that personnel wear safe work clothing.

– Make sure that the following items are not worn: • Rings • Wristwatches • Ties • Scarves • Open jackets • Loose-fitting clothing – Make sure that the following equipment for the assembly is present, in a clean, complete and undamaged condition: • Basic tool • Required devices • Required special tools – Replace damaged tools.

– Keep the workplace clean and orderly.

– Make preparations for potential emergencies that could arise.

– Keep fire extinguishers and first aid kits at hand.

– Keep emergency telephone numbers at hand.

– Ensure that the workplace is sufficiently lit.

– Perform assembly work only when the diesel engine is secured.

– Ensure that the diesel engine cannot be started by unauthorised persons.

2.6 Preventing personal injuries 2.6.1 Crushing – Do not lift heavy parts by hand.

– Carefully fasten and simultaneously secure individual parts and larger assemblies to lifting equipment during replacement.

– Use Liebherr lifting devices and operate them according to the operating instructions.

– Adhere to the stipulations for the lifting points.

– Do not use damaged lifting devices or lifting devices that do not have a sufficient load capacity.

– Make sure that no persons are residing under suspended loads.

– When the diesel engine is running: make sure that no objects come into contact with rotating parts. Objects can be catapulted out.

The diesel engine's operating temperature is hot.

– Only work on the diesel engine when it is cooled off.

– Touch hot parts with appropriate thermal protection gloves.

When the diesel engine is at operating temperature, the cooling system is hot and is under pressure.

– Touch hot parts with appropriate thermal protection gloves.

– Avoid contact with parts carrying cooling water.

– When the expansion tank end cover has cooled down: Check the cooling water level.

– Carefully open the lid in order to let off the excess pressure.

When the diesel engine is at operating temperature, the engine oil is hot.

– Avoid skin contact with hot oil or oil-bearing parts.

copyright © Liebherr Machines Bulle SA 04.0

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

LMB/10154726/04/04.07.2018/en

2.6.2 Burns and scalds

Operator's manual

Safety instructions Preventing personal injuries

2.6.3 Fires and explosions – Smoking in the immediate vicinity of the diesel engine is prohibited.

– Avoid fires, sparks and open flames when handling fuels and flammable liquids.

– Start the diesel engine according to the stipulations in the operating instructions and assembly instructions.

– Rectify leaks and replace defective parts.

Fuel and oil spraying out of leaky spots can lead to fires.

– If batteries are being worked on: Wear safety goggles and protective gloves.

– Remove cleaning cloths soaked with flammable liquids.

– If the electrical system is being worked on: Disconnect electrical power supply.

2.6.4 Poisoning – Only allow the diesel engine to run in an enclosed space if there is sufficient ventilation.

If more fresh air supply is required: Open doors and windows.

– Do not ingest operating fluids under any circumstances.

– Do not use beverage bottles for storage.

Liquids that emerge can penetrate the skin and lead to blood poisoning.

– Do not open any lines and hoses that are under pressure.

– Do not remove any lines and hoses that are under pressure.

– Protect hands, face and body against escaping liquids when searching for leaks on lines and hoses that are under pressure.

2.6.5 High-pressure injection (fluids spraying out under high pressure)

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When the diesel engine is running, the fuel lines are under a constant fuel pressure of up to 2400 bar. Liquids that emerge can penetrate the skin and lead to injuries.

– Only work on the fuel and injection system when the diesel engine is switched off.

If the diesel engine was turned off: Wait at least 20 minutes until the start of work until the pressure in the injection system has fallen.

– Check the reduction in pressure with the diagnostics program.

– Use appropriate protective equipment when working on the fuel and injection system (e.g. protective gloves, safety goggles, etc.).

– Do not open any fuel lines and hoses that are under pressure.

– Do not remove any fuel lines and hoses that are under pressure.

– Protect hands, face and body against escaping liquids when searching for leaks on lines and hoses that are under pressure.

– Move the diesel engine to a clean area of the workshop in which no work that can stir up dust is performed (grinding and welding work, brake repairs, brake and performance tests etc.).

2.6.6 Electrical energy – Persons with heart pacemakers: Keep a minimum distance of 20 cm from the operational diesel engine.

– Do not touch any live parts.

– Before working on the electrical system: Disconnect electrical power supply.

– When carrying out welding work, the batteries must be disconnected and the two cables (plus and minus) must be securely connected to each other. In addition, the connection plugs must be disconnected for all control units.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Safety instructions

Operator's manual

Personal protective equipment

2.6.7 Danger due to noise Possible permanent hearing loss due to noise level over 84dB(A). Noise level up to 110dB possible!

– Keep all noise-insulating guards of the system closed when the engine is running.

– Do not stay near the engine when it is running without hearing protection matched to the noise level.

– Observe hearing protection measures according to the operating instructions of the device manufacturer.

Access to the safety zones is prohibited for the operator and unauthorised persons when the engine is ready for operation and in operation. However, if a technician must remain near the unprotected engine for troubleshooting, he must wear hearing protection which is designed for the noise exposure.

2.7 Personal protective equipment – Wear protective equipment during direct access to the diesel engines.

– Make sure that: • Protective equipment is in good condition.

• Protective function is guaranteed.

The following protective equipment is necessary for accessing the diesel engine: Protective clothing – Closely fitting protective clothing that is not tear-resistant to protect against injuries and simple chemical substances Wear protective clothing in the immediate vicinity of the engine.

Safety helmet – Protection against falling or flying objects and against bumping your head Wear a safety helmet in the immediate vicinity of the engine.

Safety gloves – Protection against hot elements and chemicals Wear protective gloves when working with hot parts. (For example: Shrinking gear ring on flywheel.)

Wear protective gloves when working with operating fluids. (See manufacturer's information for the operating fluids and safety data sheet for the operating fluids.)

Hearing protection – Protection against noise Wear hearing protection near the diesel engine when it is running.

Safety goggles – Protection against splinters flying around and splashes from chemicals Wear safety goggles when handling operating fluids. (See manufacturer's information for the operating fluids and safety data sheet for the operating fluids.)

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

LMB/10154726/04/04.07.2018/en

Safety shoes – Foot protection against falling objects and feet getting caught in heavy parts.

Additional protection against slipping Wear safety shoes in the immediate vicinity of the engine.

Operator's manual

Safety instructions Operating areas and maintenance areas

Wear safety goggles during mechanical interventions. (For example, when using compressed air)

2.8 Operating areas and maintenance areas 2.8.1 Safety instructions Trapping hazards and flying mechanical parts when engine is operational or in operation.

Serious injuries and danger to life.

– Keep away from operational engine.

– Wear personal protective equipment.

– Technicians may reside in safety zone "A" for measurement purposes, provided that nothing else has been disclosed by the device manufacturer.

Hot parts when engine is operational or in operation.

Risk of burns.

– Keep away from operational engine.

– Wear personal protective equipment.

– Allow engine to cool down sufficiently.

High electrical short-circuit currents during maintenance work.

Risk of burns, electric shock.

– Access to safety zones in the maintenance condition according to target group definition.

– Disconnect electrical power supply.

– Wear personal protective equipment.

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2.8.2 Operating areas

Fig. 18: Safety zones of engine that is operational or in operation a

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

Horizontal section (top view)

b

Vertical section (view from flywheel side)

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Safety instructions

Operator's manual

Operating areas and maintenance areas

It is not permitted to enter the following zones: – – – – –

Safety zone, power unit carrier side A Safety zone next to engine B Safety zone, flywheel side C Safety zone above engine D Safety zone below engine E

2.8.3 Maintenance areas Maintenance areas are the safety zones that are to be entered for maintenance work and troubleshooting.

WARNING Hot parts during maintenance work.

Risk of burns. u Allow engine to cool down sufficiently. u Wear personal protective equipment.

Fig. 19: Safety zones during maintenance and repair Horizontal section (top view)

b

Vertical section (view from flywheel side) LMB/10154726/04/04.07.2018/en

a

It is permitted to enter the following zones: – – – –

Safety zone, power unit carrier side A Safety zone next to engine B Safety zone, flywheel side C Safety zone above engine D

It is not permitted to enter the following zones: – Safety zone below engine E

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

Operator's manual

Safety instructions Operating areas and maintenance areas

2.8.4 Securing and releasing the diesel engine against unexpected start-up The access to the maintenance areas must be secured against unexpected startup before entering the safety zones.

Procedure: Secure the diesel engine against unexpected start-up: – Disconnect diesel fuel supply.

– Identify disconnection point with a label.

– Disconnect the electrical energy supply and secure it against being turned back on.

– Identify disconnection point with a label.

Make diesel engine ready for operation (release): – The following activities are completed: • Installation activities • Maintenance activities • Repair activities – Make sure that all foreign objects are removed.

– All protective equipment is installed and functioning.

– Make sure that no outsiders are residing in danger areas.

– Remove the label from the fuel supply.

– Remove the disconnection from the fuel supply.

– Remove the label from the electrical energy supply.

– Establish electrical power supply.

2.8.5 Emergency stop An emergency stop exists for dangerous situations which require an immediate shutdown of the diesel engine. The energy supply to the diesel engine is immediately interrupted. Only the engine control unit continues to have power.

Examples of dangerous situations: – Fire – Person sustains electric shock – Diesel engine will not stop – Diesel engine accelerates uncontrollably Actuate the emergency stop only in emergency situations. Actuating the emergency stop can permanently damage the diesel engine. The emergency stop may not be used for an operational stop of the diesel engine.

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2.8.6 Signage Note u The signs must be clearly visible and be attached in the immediate vicinity of the safety zones. u The signs must withstand the environmental conditions. The end user must make sure that these remain visible and legible during the entire life cycle. u Additional warning symbols or adaptation to product standards (ISO 8528–13) are possible.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Safety instructions

Operator's manual

Preventing property damage

ISO 7010 / W012 Warning of dangerous, electrical voltage – Only persons who know the dangers of electricity may work in the identified area.

Unauthorised persons may only enter the safety zone when the electrical power supply is disconnected.

ISO 7010 / W017 Warning of hot surfaces – There are hot surfaces located on the diesel engine which are not immediately recognisable.

Wait a sufficient cooling time.

Touch potentially hot components with suitable protective gloves.

ISO 7010 / W025 Warning of entanglement hazard – There are potential trapping hazards on the engine in the area of the V-ribbed belts and the alternator for charging the battery.

Attach warning sign if trapping hazards are not secured through guards (optional).

Enter safety zone only when the diesel engine is turned off.

Secure the diesel engine against unexpected start-up.

ISO 7010 / P007 No access for persons with heart pacemakers or implanted defibrillators – Possible EMC radiation, which can affect heart pacemakers and implanted defibrillators.

Persons with heart pacemakers or implanted defibrillators: Keep a distance of at least 20cm (8 inches) from the operational diesel engine.

ISO 7010 / M002 Follow manual – In order to ensure that all residual risks are known by the personnel, the system documentation must be read and understood.

Make sure that all residual risks according to the risk assessment of the device manufacturer are reflected in the system documentation.

Provide documentation to the personnel according to the "target group" without restrictions.

– – – – – – – – – – –

Replace sealing material (for example, o-rings, seals, etc.).

Check reusable parts that are removed for reusability.

Replace parts that are removed that are not reusable.

If no special torques and tensioning instructions are stated: Tighten screwed assemblies according to standard torques. For more information, see the chapter "Standard torques".

Replace self-locking screwed assemblies.

Thoroughly clean diesel engine, connections and screw fittings of oil, fuel or care products before assembly.

Use lint-free cleaning cloths.

Do not touch electric contacts. The connection is affected by contamination or components are destroyed by electrostatic discharges (ESD).

Before the diesel engine is cleaned: Cover or seal openings into which no water, steam or cleaning agents may permeate due to safety reasons or functional reasons.

Remove covers or adhesions after cleaning.

Inspect fuel lines, diesel engine oil lines and hydraulic lines for the following defects: • Leaks

copyright © Liebherr Machines Bulle SA 04.0

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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2.9 Preventing property damage

Operator's manual

Safety instructions Disposal of operating fluids

– – – – –

• Loosened connections • Abrasions • Damage Ensure that the electrical power supply is securely connected when starting.

Ensure that the engine is turned off in order to disconnect the electrical power supply.

Use appropriate test outputs for measurements on plug connections.

If no mating connector is attached: Protect engine control unit against dust and water.

Disconnect the battery when working on the electrical system and also remove the plug from the control unit when carrying out electric welding work on the machine. Always disconnect negative poles first and connect them last.

2.10 Disposal of operating fluids Concerning scrap materials and hazardous waste, such as for example: – Oils, lubricant, refrigerant from air conditioning systems etc.

– Coolant – Fuels – Reducing agent – Filters, oil filter cartridges etc.

DANGER Inadvertent filling of operating fluids in food or beverage containers Operating fluids could be drunk accidentally.

Danger to health and life. u Do not use food or beverage containers to drain operating fluids! u Use leak-proof containers to drain operating fluids!

Note Danger to environment and health u Observe the country-specific regulations regarding environmental protection when disposing of used consumables. u Before disposing or recycling waste products, ask for the correct method at the responsible environmental or recycling centre. u Different operating fluids are to be collected and disposed in separate containers.

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u Make sure that no operating fluids end up in the soil, sewer system or water.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Safety instructions

Operator's manual

Exhaust after-treatment system (SCR)

2.11 Exhaust after-treatment system (SCR) NOTICE If water, steam or other cleaning agents gets into the SCR module!

The coating of the substrates peels off.

NOx sensor defective. u Cover all openings before cleaning. u Make sure that no liquids or dirt get into the tail pipe opening on the SCR module.

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u Allow the exhaust after-treatment system to cool down before cleaning (surface temperature < 50 °C.

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

3 Operation

3.1 Indicator and warning lamps The indicator and warning lamps are part of the devices and are described in the manufacturer's documentation.

Data, for example in relation to oil pressure, coolant temperature, speed, operating hours and service code, is transmitted to the device for operation and control of the diesel engine via the electronic interface on the diesel engine.

Exhaust after-treatment system indicator and warning lamps The different statuses of the exhaust after-treatment system are shown to the operator by the illumination of the corresponding indicator lights on the display. The pictograms are for example purposes and can differ in the various devices.

Lamp

Designation

Meaning

Remedy

Exhaust after-treatment system malfunction or reducing agent tank fill level not OK

Top up the reducing agent and/or contact Liebherr customer service

MIL lamp (Malfunction Indicator Lamp)

MIL lamp (used

by LWE)

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DEF lamp

Tab. 6: SCR indicator and warning lamps

Warning and malfunction strategies The exhaust after-treatment system is monitored by a diagnostics system. If the diagnostics system detects an error, a warning or malfunction strategy is activated.

Attempting to operate the unit with a malfunction for more than four operating hours will mean that the power limitation cannot be deactivated even by turning off the ignition. A repair of the device is absolutely necessary. If another error is detected within 40 operating hours of the problem being rectified, then the limita-

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Operation

Operator's manual

Indicator and warning lamps

tions will be applied after shorter intervals. The final limitation of the system will occur within one operating hour.

Note

LMB/10154726/04/04.07.2018/en

u The limitations will not occur all of a sudden, but gradually.

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

Operator's manual

Operation Indicator and warning lamps

EU strategies (Stage IV) / US-EPA/CARB (Tier4) Application

On-screen display

System status

Limitation

MIL off

DEF yellow

DEF level < 10% or exhaust after-treatment system No limitation malfunction 0 min 60 min

Signal tone

MIL yellow

DEF yellow

Stationary applications for mobile cranes (OW)

DEF level < 5% or exhaust after-treatTorque limited to ment system 75% malfunction 60 min 180 min

Signal tone

MIL yellow

DEF red

DEF level < 2.5% or exhaust after-treatTorque limited to ment system 20% malfunction 180 min - 210 min

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Signal tone

MIL red

DEF red

DEF level = 0 or exhaust after-treatment system malfunction from 210 min

Torque limited to 20%

Signal tone

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Operation

Operator's manual

Indicator and warning lamps

Application

On-screen display

System status

Limitation

MIL off

DEF yellow

DEF level < 10% or exhaust after-treatment system No limitation malfunction 0 min 60 min

Signal tone

MIL yellow, flashing

DEF yellow

On-road applications for mobile cranes (UW)

DEF level < 5% or exhaust after-treat- Maximum vehicle ment system speed malfunction 60 min - 72 kmh (45 mph) 180 min

Signal tone

MIL yellow, flashing

DEF yellow, flashing

DEF level < 2.5% or exhaust after-treat- Maximum vehicle ment system speed malfunction 180 min 8 kmh (5 mph) - 210 min

MIL yellow

DEF yellow, flashing

DEF level < 0% or exhaust after-treatment system malfunction from 210 min

Maximum vehicle speed 8 kmh (5 mph)

Signal tone copyright © Liebherr Machines Bulle SA 04.0

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

LMB/10154726/04/04.07.2018/en

Signal tone

Operator's manual

Operation Indicator and warning lamps

Application

On-screen display

System status

Limitation

MIL off

DEF yellow

DEF level < 10% or exhaust after-treatment system No limitation malfunction 0 min 60 min

Signal tone

MIL yellow

DEF yellow

Off-road applications

DEF level < 5% or exhaust after-treatTorque limited to ment system 75% malfunction 60 min 180 min

Signal tone

MIL yellow

DEF red

DEF level < 2.5 % or exhaust afterTorque limited to treatment system 20% malfunction 180 min - 210 min

LMB/10154726/04/04.07.2018/en

Signal tone

MIL red

DEF red

DEF level < 0% or exhaust after-treatment system malfunction from 210 min

Torque limited to 20%

Signal tone Tab. 7: EU strategies (Stage IV) / US-EPA/CARB (Tier4) D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Operation

Operator's manual

Indicator and warning lamps

Attempting to operate the unit with a malfunction for more than 4 operating hours will mean that the power limitation cannot be deactivated even by turning off the ignition. A repair of the device is absolutely necessary. If another error is detected within 40 operating hours of the problem being rectified, then the limitations will be applied after shorter intervals. The final limitation of the system will occur within one operating hour.

Note u The limitations will not occur all of a sudden, but gradually.

DANGER Lower vehicle speed for on-road applications for mobile cranes (UW)!

Traffic blocks/increased risk of accidents u Observe the on-screen display.

LMB/10154726/04/04.07.2018/en

u Top up the reducing agent in good time or contact Liebherr customer service.

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

Operator's manual

Operation Starting the engine

3.2 Starting the engine 3.2.1 Preceding work for the initial commissioning of the engine u Check engine for proper installation, see documentation from the device manufacturer. u Provide a suitable engine oil for the engine. u Fill the oil. u Check the oil filter connection. u Provide coolant with the correct coolant composition. u Fill the coolant, see documentation from the device manufacturer. u Check the connections for the coolant lines. u Connect the air intake, see documentation from the device manufacturer. u Connect the exhaust after-treatment system, see documentation from the device manufacturer. u Connect the fuel supply, see documentation from the device manufacturer. u Provide diesel fuel with the approved fuel specification. u Fill the diesel fuel. u Vent the fuel system. u Check the fuel prefilter connection, see documentation from the device manufacturer. u Check the fuel fine filter connection. u Connect the electrical voltage supply, see documentation from the device manufacturer. u Upload the current software update to the engine control unit.

LMB/10154726/04/04.07.2018/en

3.2.2 Starting the engine Make sure that the following requirements are met: q During the initial commissioning: Preceding work for the initial commissioning of the engine is completed. q The oil level is correct. q The coolant is filled, see documentation from the device manufacturer. q The charge air is connected, see documentation from the device manufacturer. q Exhaust disposal is guaranteed. q Electrical voltage supply is ready. q Fuel supply is connected. q Every eight operating hours: Perform the required activities from the maintenance schedule.

DANGER Sudden movement of the engine!

Death. u Do not start the engine by bypassing the starter.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Operation

Operator's manual

Starting the engine

WARNING Hot starter!

Burns. u Keep people, vehicle parts or media away from the starter during the start process. u Keep people, vehicle parts or media away from the starter after the start process. u Before working on the starter, wait until the starter has cooled down to ambient temperature. u Disconnect the energy supply before working on the starter.

DANGER Unexpected movement of the system!

Death. u Make sure that no persons are residing in danger areas of the engine. u Bring all protective equipment into the protective position. u Close the housing. u Secure the external parts against unexpected movement.

NOTICE Insufficient lubrication!

Damage to engine. u Make sure that the oil pressure builds up immediately after starting the engine.

If the oil pressure warning light does not go out within 5 seconds: u Turn off the engine immediately. u Determine cause and rectify.

NOTICE Continuous actuation!

Damage to starter. u Let the starter run for a maximum of 30 seconds. u Start the engine.

If the engine will not start: u Wait at least two minutes before the next attempt.

If the engine will not start during the second attempt: u Wait at least five minutes before the next attempt. u Start the engine.

If the engine will not start during the third attempt: u Determine cause and rectify. u Check the oil pressure gauge immediately after starting the engine.

If no oil pressure is built up within 5 seconds: u Turn off the engine immediately. u Determine cause and rectify.

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

LMB/10154726/04/04.07.2018/en

u Start the engine.

Operator's manual

Operation Starting the engine

NOTICE Impermissible loading of the engine in a cold state!

Damage to engine. u Let the engine warm up until the operating temperature has been reached.

If the engine start was successful: u Warm up the engine. w Coolant temperature >60 °C u Shut off the engine. u Check the engine oil level. u Check coolant level, see documentation from the device manufacturer. u Make sure visually that there are no leaks to be found on the lines of the oil system. u Make sure visually that there are no leaks to be found on the lines of the fuel system.

3.2.3 Shutting off the engine NOTICE Shutting off the engine at full load speed!

Damage to engine. u Shut off the engine at idle running speed. u Reduce the engine speed to idle running speed. u Let the engine idle for 15 s.

LMB/10154726/04/04.07.2018/en

u Shut off the engine.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Operation

Operator's manual

Exhaust after-treatment system

3.3 Exhaust after-treatment system

Fig. 67: Exhaust after-treatment system 1 2 3 4

Diesel engine Air intake Exhaust turbocharger Reducing agent and air injector

5 6 7

Reducing agent pump system Reducing agent tank SCR module

The SCR exhaust after-treatment system (selective catalytic reduction) describes a technique for converting or reducing nitrogen oxides (NOx) in the exhaust gas by adding a reducing agent (water/urea solution) into nitrogen (N2) and water (H2O).

3.3.1 Handling / use of NO reducing agent X

CAUTION Reducing agent can cause injuries to the eyes and allergic skin reactions. u Avoid skin contact with reducing agent. u Note manufacturer instructions.

Note If reducing agent comes into contact with painted or aluminium surfaces during filling: u Wash off the affected areas immediately with water.

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

LMB/10154726/04/04.07.2018/en

Safety instructions

Operator's manual

Operation Exhaust after-treatment system

NOTICE Mixing in special additives and dilution of the reducing agent (for example, with tap water) are not permitted.

Statutory exhaust gas limits will be exceeded.

Destruction of the exhaust after-treatment system. u Do not mix reducing agent with special additives or dilute it. u Make sure that no dirt gets into the reducing agent. u Do not fill the reducing agent tank with operating fluids. u Do not fill the diesel fuel tank with reducing agent.

NOTICE If diesel fuel is poured into the reducing agent tank, or vice-versa. u Do not start the diesel engine. u Contact Liebherr customer service.

NOTICE Contamination of the reducing agent Destruction of the exhaust after-treatment system u Keep the reducing agent absolutely clean. u Do not reuse drained reducing agent.

Disposal

LMB/10154726/04/04.07.2018/en

u Dispose of reducing agent in an environmentally friendly manner.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Operation

Operator's manual

LMB/10154726/04/04.07.2018/en

Exhaust after-treatment system

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

4 Operating faults

Troubleshooting with diesel engines can be difficult. For some diesel engine problems with possible cause and corrective measures see the table Faults - Cause Remedy.

Note

Diesel engine faults are displayed by means of a fault code on the device display for diagnostic purposes. The explanation and remedies are explained in the respective device documentation.

Tab. 8 Basic logical steps for diagnosis are contained in the following list: – Know the diesel engine and the associated systems.

– Thoroughly study the problem.

– Relate symptoms to existing knowledge about the diesel engine and systems.

– Diagnose problem, starting with the most obvious assumptions.

– Examine closely before starting to take the engine apart.

– Identify the causes and perform repair work thoroughly.

– After repair, run the diesel engine under normal operating conditions and check whether the problem and its cause have been remedied.

LMB/10154726/04/04.07.2018/en

4.1 Faults - Cause - Remedy Malfunction / error

Cause

Remedy

Starter does not turn

Main fuse blown

Replace fuse.

Battery connections loose or corroded

Clean and tighten loose connections.

Battery voltage too low

Recharge or replace battery.

Starter circuit broken or contacts corroded.

Contact Liebherr customer service.

Starter defective

Contact Liebherr customer service.

Battery voltage too low

Recharge or replace battery.

Battery connections loose or corroded

Clean and tighten loose connections.

Outdoor temperature too low

Implement measures for winter operation.

Starter turns over slowly

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Operating faults

Operator's manual

Faults - Cause - Remedy

Malfunction / error

Cause

Remedy

Diesel engine does not start or comes immediately to halt again.

Fuel tank empty

Refuel, vent fuel system.

Fuel filter blocked

Replace fuel filter.

Fuel line, precleaner or sieve in fuel tank blocked

Clean and vent fuel system.

Fuel system or filter leaking

Seal and vent.

Air in the fuel system

Vent fuel system.

Fuel not cold-resistant

Clean pre-filter, replace fuel filter; use winter fuel.

Outdoor temperature too low

Implement measures for winter operation.

Heating flange defective (at low temperatures)

Check heating flange, replace if necessary.

Diesel engine starts poorly.

Diesel engine shuts down when not desired.

Leaks or pressure too low in fuel low Leak testing (visual inspection); get pressure circuit Liebherr customer service to check engine Diesel engine compression too low

Contact Liebherr customer service.

Heating flange defective (at low temperatures)

Check heating flange, replace if necessary.

Fault in electronics

Read out fault memory of engine control unit, contact Liebherr customer service.

Voltage supply interrupted

Contact Liebherr customer service.

Leaks or pressure too low in fuel low Leak testing (visual inspection); get pressure circuit Liebherr customer service to check engine Read out fault memory of engine control unit, contact Liebherr customer service.

LMB/10154726/04/04.07.2018/en

Fault in electronics

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

Operator's manual

Operating faults Faults - Cause - Remedy

Malfunction / error

Cause

Remedy

Low diesel engine power (lack of power)

Defect in fuel system (blocked, leaking)

Visual inspection for leaks, change filter, contact Liebherr customer service.

Charging pressure too low

Loose clips, defective seals and hoses, air filter contaminated, turbocharger has no power.

Charging air temperature too high (automatic power reduction by engine control unit)

Charge air cooler contaminated, low fan power, ambient temperature too high, contact Liebherr customer service.

Coolant temperature too high (automatic power reduction by engine control unit)

Check cooler for contamination, check fan and thermostat, check coolant level, contact Liebherr customer service.

Fuel temperature too high (automatic power reduction by engine control unit)

Contact Liebherr customer service.

Use at elevation over 1800 m above No remedy, diesel engine power has sea level been automatically reduced.

Poor diesel engine braking

LMB/10154726/04/04.07.2018/en

Diesel engine gets too hot (according to coolant temperature display)

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

Injection nozzles stuck or do not vaporise.

Contact Liebherr customer service.

Diesel engine compression too low

Contact Liebherr customer service.

Fault in electronics

Read out fault memory of engine control unit, contact Liebherr customer service.

Exhaust after-treatment system blocked

Contact Liebherr customer service.

Diesel engine brake flap does not function

Functional and visual check; contact Liebherr customer service.

Electronics fault

Contact Liebherr customer service.

Too little coolant

Replenish

Cooler internally contaminated or scaled, outside of cooler heavily contaminated

Clean or descale.

Thermostat defective

Check, replace if necessary, contact Liebherr customer service.

Coolant temperature sensor defective

Check, replace if necessary, contact Liebherr customer service.

Fan speed too low (hydrostatic fan drive only)

Check fan drive, replace if necessary, contact Liebherr customer service.

copyright © Liebherr Machines Bulle SA 04.0

43

Operating faults

Operator's manual

Malfunction / error

Cause

Remedy

Charge current indicator light illuminates when diesel engine running

V-ribbed belt tension insufficient

Check V-ribbed belt tension, if necessary replace tensioning roller.

V-ribbed belt torn

Replace V-ribbed belt.

Cable connections loose or separated

Fix or replace cable.

Alternator, rectifier or regulator defective

Contact Liebherr customer service.

Black smoke from diesel engine.

Exhaust after-treatment system defective

Contact Liebherr customer service.

Exhaust gases blue.

Oil level in the diesel engine too high Adjust oil level.

Lubricating oil is reaching the combustion chamber and is being burned.

Contact Liebherr customer service.

Compressor-side seal on the exhaust gas turbocharger defective

Contact Liebherr customer service.

Crankcase ventilation defective

Check, if necessary replace.

Injection start too late

Contact Liebherr customer service.

Heating flange defective (at low temperatures)

Check heating flange and replace if necessary.

Diesel engine rattles.

Combustion faults

Contact Liebherr customer service.

Diesel engine knocking.

Valve clearance too great

Set valve clearance.

Injection nozzles damaged or carbonised

Contact Liebherr customer service.

Bearing damage

Contact Liebherr customer service.

Piston rings worn or broken, pistons eroded

Contact Liebherr customer service.

Leaks in the suction and exhaust lines cause whistling noise.

Seal leaks, replace seal if necessary.

Turbine or compressor wheel rubbing against the housing; foreign bodies in the compressor or turbine; seized up bearings of rotating parts

Contact Liebherr customer service.

Oil level in the oil pan too low

Fill oil to prescribed mark.

Lubricating oil is too thin (oil diluted by diesel fuel)

Drain off oil, fill with prescribed oil.

Pressure sensor defective

Check oil pressure and replace damaged oil pressure sensor; contact Liebherr customer service.

End control valve does not work properly or dirt in the end control valve.

Contact Liebherr customer service.

Bearing clearance too great due to wear or bearing damage

Contact Liebherr customer service.

Oil cooler or oil cooler plate leaking

Contact Liebherr customer service.

Exhaust gases white.

Abnormal noises

Lubricating oil pressure too low

Lubricating oil in the cooling system

copyright © Liebherr Machines Bulle SA 04.0

44

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

LMB/10154726/04/04.07.2018/en

Faults - Cause - Remedy

Operator's manual

Operating faults Faults - Cause - Remedy

Cause

Remedy

Cooling water in the lubricating oil

O-rings on the cylinder liners are leaking

Contact Liebherr customer service.

Oil cooler or oil cooler plate leaking

Contact Liebherr customer service.

LMB/10154726/04/04.07.2018/en

Malfunction / error

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

copyright © Liebherr Machines Bulle SA 04.0

45

Operating faults

Operator's manual

LMB/10154726/04/04.07.2018/en

Faults - Cause - Remedy

copyright © Liebherr Machines Bulle SA 04.0

46

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

5 Maintenance

5.1 Maintenance and inspection schedule Abbreviations h = operating hours Note When operating at less than ideal conditions, such as intense heat, dust-laden air or poor fuel quality, more frequent maintenance than scheduled in the inspection plan can be required.

Power groups LG 0 — LG 2

Mobile construction crane (MK crane), mobile crane, crawler crane, duty-cycle crawler crane, crawler crane, rotary drilling rigs, piling and drilling rigs (LRB series), hanging or swing leader (LRH series), reachstacker, maritime crane

LG 3 — LG 5

Crawler excavator, demolition excavator, wheeled excavators, articulated dumper truck, wheel loader, crawler tractor, crawler loader, pipe layer, mobile material handling machines, crawler material handling machines

LMB/10154726/04/04.07.2018/en

Tab. 9: Devices

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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47

Maintenance

Operator's manual

Maintenance and inspection schedule Customer:.......................... Machine type:.....................................Serial no.:...................Operating hours:.....................Date:.................................

Tasks to be performed By maintenance staff n Once-only activity l Repeat interval ª If necessary T Annually before the winter

Other intervals

All 3000 h

All 2000 h

All 500 h

All 1000 h

All 50 h

All 8-10 h

On handover

Maintenance / inspection after service hours

By authorised specialist staff o Once-only activity m Repeat interval ² If necessary

Diesel engine l l l m m m

Check engine oil level (or use oil level sensor reading in vehicle cab)

l l l m m m

Visual inspection (leaks, contaminations, damage) Check state of belt drive, replace if necessary.

l m m m 5000h

Replace belt drive (at least every 5 years).

n m m m

Check intake and exhaust system for condition, seating and leaks.

m m m

Check that engine bearing and diesel engine console are securely seated.

Check heating flange.

T

m10000h Replace heating flange.

Replace diesel engine oil (at least every 2 years). m

m1500h

Stage IV / Tier 4 diesel engines of power group 0 — 2 (LG see chapter 5.1). Valid for OEM products from Liebherr such as Liebherr engine oil 5W30.

Stage IV / Tier 4 diesel engines of power group 3 — 5 (LG see chapter 5.1). Valid for OEM products from Liebherr such as Liebherr engine oil 5W30.

m

Diesel engines without emission type approval

m m m

Replace oil filter (at least every 2 years). m

m1500h

Stage IV / Tier 4 diesel engines of power group 0 — 2 (LG see chapter 5.1). Valid for OEM products from Liebherr such as Liebherr engine oil 5W30.

Stage IV / Tier 4 diesel engines of power group 3 — 5 (LG see chapter 5.1). Valid for OEM products from Liebherr such as Liebherr engine oil 5W30.

m

Diesel engines without emission type approval

m m m

Replace the oil separator filter insert. m1500h

Stage IV / Tier 4 diesel engines of power group 0 — 2 (LG see chapter 5.1). Valid for OEM products from Liebherr such as Liebherr engine oil 5W30.

Stage IV / Tier 4 diesel engines of power group 3 — 5 (LG see chapter 5.1). Valid for OEM products from Liebherr such as Liebherr engine oil 5W30.

m

Diesel engines without emission type approval

m m m

Check / set valve clearance. m

m1500h

Stage IV / Tier 4 diesel engines of power group 0 — 2 (LG see chapter 5.1)

m4000h

D934 A7–04 / D936 A7–04 Stage IV / Tier 4 diesel engines of power group 3 — 5 (LG see chapter 5.1)

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48

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

LMB/10154726/04/04.07.2018/en

m

Operator's manual

Maintenance Maintenance and inspection schedule

Customer:.......................... Machine type:.....................................Serial no.:...................Operating hours:.....................Date:.................................

Tasks to be performed By maintenance staff n Once-only activity l Repeat interval ª If necessary T Annually before the winter

Other intervals

All 3000 h

All 2000 h

All 500 h

All 1000 h

All 50 h

All 8-10 h

On handover

Maintenance / inspection after service hours

By authorised specialist staff o Once-only activity m Repeat interval ² If necessary

D944 A7–04 / D946 A7–04 Stage IV / Tier 4 diesel engines of power group 3 — 5 (LG see chapter 5.1)

m m

m1500h

Diesel engines without emission type approval Cooling system Check coolant level.

l l l m m m

Check cooling and heating system for condition and leaks.

l m m m m

T m6000h

Check corrosion protection and antifreeze concentration in the coolant (at least once per year).

Replace coolant (at least every 4 years) when using Liebherr Antifreeze OS. Fuel system Check water trap on the fuel prefilter and if necessary drain water.

l l l m m m

Drain water and sediments from fuel tank.

l l m m m

Check the condition of the lubricating oil and fuel system and check for leaks.

l m m m m m m

Replace fuel prefilter (or in case of low performance).

m m m

Replace fuel fine filter (or in case of low performance). ²

Vent fuel system (injection lines may not be detached) Air filter Check underpressure display of the air filter.

l l l m m m

Clean the dust extraction valve of the air filter.

l l m m m ²

Replace dry air filter main element (after maintenance indicator / annually)

²

Replace dry air filter safety element (with every 3rd change of the main element / annually)

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Electrical system n m m m

Check batteries and cable connections.

l m m m

Check condition of control unit bearings.

n m m m

Check condition of sensors, actuators, cable holders and plugs.

Exhaust after-treatment system

l l l m m m n l m m m

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

Visual inspection of exhaust after-treatment system Check that profile clip is tightened to the correct torque.

copyright © Liebherr Machines Bulle SA 04.0

49

Maintenance

Operator's manual

Fill quantities

5.2 Fill quantities 5.2.1 Lubricants and operating fluids Designation

Quantity

Engine type

Engine oil

25 l (1.5 l per filter)

D934 A7–04 / D944 A7–04 / D934 A7– 00 / D944 A7–00

44 l (1.5 l per filter)

D936 A7–04 / D946 A7–04 / D936 A7– 00 / D946 A7–00

15 l

D934 A7–04 / D944 A7–04 / D934 A7– 00 / D944 A7–00

20 l

D936 A7–04 / D946 A7–04 / D936 A7– 00 / D946 A7–00

Coolant

Reducing agent See documentation from the device manufacturer.

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Tab. 10: Initial filling guideline values

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

Operator's manual

Maintenance Lubricants and operating fluids

5.3 Lubricants and operating fluids 5.3.1 Diesel fuels Minimum quality requirements Permitted diesel fuels according For Stage IV / Tier to DIN EN 590 and ASTM D975 4 diesel engines 1–D / 2–D

For diesel engines without emission type approval

Maximum sulphur content in fuel

≤ 15 ppm

≤ 5000 ppm

Lubricating ability at 60°C

≤ 460 µm

≤ 460 µm

Minimum cetane number

45

45

Tab. 11: Minimum requirement for diesel fuels Specification LH-00-FUEL Tab. 12: Specification for diesel fuels

5.3.2 Reducing agent Permitted reducing agent: – Reducing agent standardised according to ISO 22241 Designations: – AdBlue® in Europe – DEF (diesel exhaust fluid) in the USA – AUS 32 (aqueous urea solution) Specification LH-00–UREA Tab. 13: Specification for reducing agent for better results

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5.3.3 Engine oils Liebherr recommends for Stage IV / Tier 4 diesel engines Lubricating oil change intervals for engine oils with Liebherr approval Difficulty factor

Minimum quality requirements

Liebherr engine oil

LH-00-ENG LA

Liebherr Motoroil 5W-30 Liebherr Motoroil 10W-40

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Maintenance

Operator's manual

Lubricants and operating fluids

Difficulty factor

Minimum quality requirements

Liebherr engine oil Liebherr Motoroil 5W-30, low ash Liebherr Motoroil 10W-40, low ash

Sulphur content in fuel

Interval (h = operating hours)

up to 15 ppm

50 %

Standard interval 100 % (according to maintenance schedule)

Tab. 14: Oil change intervals Note Use of engine oils from other manufacturers u Obtain information on the change intervals from the respective manufacturer or supplier.

Liebherr recommends for engines without emission type approval Lubricating oil change intervals for engine oils with Liebherr approval Difficulty factor

Minimum quality requirements

Liebherr engine oil

LH-00-ENG

Liebherr Motoroil 5W-30 Liebherr Motoroil 10W-40

Sulphur content in fuel

Interval (h = operating hours)

up to 300 ppm

50 %

Standard interval 100 % (according to maintenance schedule)

300 - 2000 ppm

25 %

50 %

2000 - 5000 ppm

12.5 %

25 %

Note Use of engine oils from other manufacturers u Obtain information on the change intervals from the respective manufacturer or supplier.

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52

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

LMB/10154726/04/04.07.2018/en

Tab. 15: Oil change intervals

Operator's manual

Maintenance Lubricants and operating fluids

5.3.4 Coolant Note It is possible that mixing different corrosion protection agents / antifreezes will impair the properties of the coolant. u Avoid combining different products. u Make sure that silicate-containing and silicate-free coolants are not mixed.

Corrosion frost protection agent Liebherr recommendation Type

Designation

PremixA) Liebherr Antifreeze OS Mix Tab. 16: Recommendations for corrosion frost protection agent A)

Premix = ready mixture (50 % water of recommended quality and 50 % corrosion frost protection agent)

Minimum quality requirements Specification LH-01-COL Tab. 17: Minimum requirements for corrosion frost protection agents

Water Liebherr recommends water with the following qualities: Corresponds to the guideline for drinking water from the World Health Organisation (WHO) from 2006 Demineralised water (reverse osmosis water)

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Tab. 18: Requirements for the water

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

copyright © Liebherr Machines Bulle SA 04.0

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Maintenance

Operator's manual

Special tools for maintenance activities

5.4 Special tools for maintenance activities

Fig. 69: Turning device - Flywheel housing attachment special tool no. 30 The turning device special tool no. 30 is optional and can be attached to any flywheel housing.

No.

ID no.

Designation

See section

30

0524045

Turning device

Check / set valve clearance

Fig. 70: Turning device - Crankshaft belt pulley attachment special tool no. 30a The turning device special tool no. 30a is only included in the scope of delivery and attached to the diesel engine as a special case.

No.

ID no.

Designation

See section

30a

10116805

Turning device

Check / set valve clearance

Tab. 20

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

LMB/10154726/04/04.07.2018/en

Tab. 19

Operator's manual

Maintenance Special tools for maintenance activities

Fig. 71: Turning device - Crankshaft belt pulley attachment special tool no. 30c Can only be used if the vibration damper is screwed together with hexagon socket screws.

No.

ID no.

Designation

See section

30c

10118801

Turning device

Check / set valve clearance

Tab. 21

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Fig. 72: Turning device - Auxiliary output NA4 attachment special tool no. 30d The turning device special tool no. 30d is optional and is not included in the scope of delivery of the diesel engine. Can only be used if auxiliary output 4 is accessible.

No.

ID no.

Designation

See section

30d

10134822

Turning device

Check / set valve clearance

Tab. 22

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Maintenance

Operator's manual

Special tools for maintenance activities

Fig. 73: Turning device - Auxiliary output NA2 attachment special tool no. 30e The turning device special tool no. 30e can only be mounted if the intermediate wheel is included in the scope of delivery of the diesel engine (not standard).

No.

ID no.

Designation

See section

30e

10138480

Turning device

Check / set valve clearance

LMB/10154726/04/04.07.2018/en

Tab. 23

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

Operator's manual

Maintenance Preparatory maintenance activities

5.5 Preparatory maintenance activities Before performing various maintenance work, the diesel engine must be brought into the maintenance position, unless otherwise specified.

This work includes: – Oil level check or oil change.

– Filter change, as well as setting work and repair work.

Safety precautions for maintenance The safety regulations must be followed while performing maintenance work as a matter of principle! See “Safety regulations” chapter.

Maintenance position

LMB/10154726/04/04.07.2018/en

The diesel engine is in the maintenance position when: – The diesel engine is horizontal.

– The diesel engine is turned off.

– The diesel engine has cooled down to the ambient temperature.

– The battery main switch, if present, is turned off and the main switch key is removed.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Maintenance

Operator's manual

Maintenance activities (daily) every 10 operating hours

5.6 Maintenance activities (daily) every 10 operating hours Make sure that: q The diesel engine is in the maintenance position.

5.6.1 Checking the engine oil level The oil dipstick and the oil filler neck is arranged differently depending on the diesel engine, e.g. oil dipstick on the left or right side of the engine, oil filler neck located on the oil pan, flywheel housing or cylinder head cover.

Fig. 74: Example of oil dipstick - Oil filler neck u Pull out oil dipstick 2, wipe with clean cloth and reinsert it to the limit stop. u Pull out the oil dipstick again and determine the oil level. The oil level must be between the “min.” and “max.” marks.

Note Check the engine oil level using the oil level sensor reading.

If the oil level is too low: u Remove oil filling cap. u Replenish oil via the oil filler neck 1. u Do not replenish diesel engine with oil over the “max.” mark. u Clean filling cap, place on the filler neck and tighten.

5.6.2 Visual inspection (leaks, contaminations, damage) u Perform visual check of diesel engine for leaks.

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

LMB/10154726/04/04.07.2018/en

u See documentation from the device manufacturer.

Operator's manual

Maintenance Maintenance activities (daily) every 10 operating hours

u Perform visual check of lines and hoses for leaks. u Check lines and hoses for undamaged condition, that they are laid free from chafing and are properly secured.

5.6.3 Checking the coolant level DANGER Hot cooler parts and hot cooler fluid!

Risk of burns. u Only perform maintenance and inspection work on the cooling system when the diesel engine has cooled down. u Wear protective equipment.

See documentation from the device manufacturer for procedure for checking coolant level.

5.6.4 Checking / draining water trap on the fuel prefilter Make sure that: q A container with the required capacity is ready.

The location of the fuel prefilter with water trap and manual fuel feed pump is removed from the diesel engine and the attachment method depends on the device design.

WARNING Naked flames!

Fire and explosion. u Avoid naked flames or lights when performing maintenance or inspection work on the fuel system.

LMB/10154726/04/04.07.2018/en

u Only perform maintenance and inspection work when the diesel engine has been shut down.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Maintenance

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Maintenance activities (daily) every 10 operating hours

Draining fuel prefilter

Fig. 75: Draining fuel prefilter u Check the fuel prefilter water trap.

Troubleshooting Have you found water in the fuel prefilter water trap? u Do not start the diesel engine. u Place receptacle under the water trap. u Loosen the venting screw 1 by turning it through two revolutions (anticlockwise). u To open the shut-off cock: Push the toggle 2 and at the same time turn it 90° anticlockwise.

When the water has been drained off: u Close the shut-off cock. Turn the toggle 2 90° clockwise (the toggle snaps back into place automatically).

LMB/10154726/04/04.07.2018/en

u Close the air venting screw with a torque of 6 Nm.

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

Operator's manual

Maintenance Maintenance activities (daily) every 10 operating hours

Venting the fuel prefilter

Fig. 76: Venting the fuel prefilter u Turn the “PUMP” mark 2a in the direction of the arrow (clockwise). u Keep actuating manual feed pump 2b until a strong resistance is felt.

In order to start the diesel engine: u Turn the “RUN” mark 2c in the direction of the arrow (anticlockwise).

5.6.5 Checking the underpressure display of the air filter See documentation from the device manufacturer for procedure for checking underpressure display of air filter.

5.6.6 Visual inspection of exhaust after-treatment system u Carry out a visual inspection of the exhaust after-treatment system for leaks and tight fit. u Check the interfaces between the exhaust gas turbocharger outlet and the exhaust after-treatment system inlet, as well as the pipes for leaks.

LMB/10154726/04/04.07.2018/en

u Check the reducing agent line between the dosing and injection unit for leaks.

Troubleshooting Have you detected leaks or fittings that are not tight? u Do not start the diesel engine. u Rectify cause.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Maintenance

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Maintenance activities every 50 operating hours (weekly)

5.7 Maintenance activities every 50 operating hours (weekly) Make sure that: q The diesel engine is in the maintenance position.

5.7.1 Draining water and sediments from the fuel tank WARNING Naked flames!

Fire and explosion. u Avoid naked flames or lights when performing maintenance or inspection work on the fuel system. u Only perform maintenance and inspection work when the diesel engine has been shut down.

For procedure for draining off water and sediments in the fuel tank, see the device manufacturer's documentation.

When refuelling, keep the fuel level in the tank as high as possible to prevent condensation to the extent possible.

5.7.2 Clean the dust extraction valve of the air filter See documentation from the device manufacturer for procedure for cleaning dust extraction valve of the air filter.

5.7.3 Inspecting the exhaust after-treatment system profile clips Note Control interval is at 500 h. u Perform this maintenance work only once at 50 h.

u Allow the exhaust after-treatment system to cool off.

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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CAUTION Hot parts!

Risk of burns.

Operator's manual

Maintenance Maintenance activities every 50 operating hours (weekly)

Fig. 77: Exhaust after-treatment system clip u Check that profile clip 1 is tightened to the correct torque (9 +2/-1 Nm).

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u Re-tighten the screw.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Maintenance activities every 500 operating hours

5.8 Maintenance activities every 500 operating hours Make sure that: q The diesel engine is in the maintenance position.

5.8.1 Checking state of belt drive and replacing, if necessary Damage to the V-ribbed belt includes: q Rib breaks. q Rubber nodules in the belt base. q Deposits of dirt and / or stones. q Ribs detached from belt base. q Traverse cracks on the back. q Traverse cracks in several ribs.

The belt attachment is self-tensioning and maintenance-free.

The belt drive is located at the front of the diesel engine.

The V-ribbed belt run varies according to the scope of delivery of the diesel engine, e.g. for alternator and alternator drive with A/C compressor.

WARNING Rotating components! u Shut down the diesel engine. u Be aware of the run-down time; before opening the covers, make sure that no parts are still moving. u Remove V-ribbed belt guard (optional). u Check V-ribbed belt for damage. u Check that the deflection rollers and tensioning device are in perfect condition and check their play (e.g. worn out bearings on the tensioning device or tread wear on the deflection rollers).

Troubleshooting Do you notice any damage?

5.8.2 Checking the intake and exhaust system for condition and leaks Note Control interval is at 1000 h. u Perform this maintenance work only once at 500 h. u Check intake lines between air filter and diesel engine for condition, leaks and tight fit. u Check exhaust lines for condition, leaks and tight fit.

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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u Replace the damaged parts. (See: chapter “Replacing the belt drive”)

Operator's manual

Maintenance Maintenance activities every 500 operating hours

5.8.3 Check cooling and heating system for condition and leaks DANGER Hot cooler parts and hot cooler fluid!

Risk of burns. u Only perform maintenance and inspection work on the cooling system when the diesel engine has cooled down. u Wear protective equipment. u Check cooler, coolant pump and heat exchanger for the heating system for leaks. u Check all lines and hoses of the cooling and heating system for leaks, undamaged condition, and that they are laid free from chafing and properly secured. u Check cooler for external contamination. The fins may not be blocked with dirt.

Troubleshooting If leaks are discovered in the cooling system: u Do not start the diesel engine. u Rectify cause.

5.8.4 Checking the lubricant and fuel system for condition and leaks u Check the oil pan, oil filter fuel feed pump and fuel filter for leaks. u Check all lines and hoses of the oil and fuel system for leaks, undamaged condition, and that they are laid free from chafing and properly secured.

Troubleshooting Have you identified leaks in the oil and fuel system? u Do not start the diesel engine. u Identify and rectify the cause as well as replacing damaged parts. (See: Repair manual)

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5.8.5 Checking the batteries and cable connections Note Control interval is at 1000 h. u Perform this maintenance work only once at 500 h.

See documentation from the device manufacturer for procedure for checking batteries and cable connections.

5.8.6 Check condition of control unit bearings u Check control unit mounting for damage and that it is firmly seated.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Maintenance activities every 500 operating hours

Troubleshooting Do you notice any damaged bearings? u Do not start the diesel engine. u Replace all bearings.

5.8.7 Check condition of sensors, actuators, cable holders and plugs Note Control interval is at 1000 h. u Perform this maintenance work only once at 500 h. u Check that all sensors, actuators, cable connections and plugs are firmly seated and check their condition. u Check the condition of cables and the cable harness, check that they have been laid so as to avoid chafing and that they are properly secured.

Troubleshooting Have you noticed damage to cable connections, cable harness or sensors? u Do not start the diesel engine.

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u Replace defective parts.

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

Operator's manual

Maintenance Maintenance activities every 1000 operating hours

5.9 Maintenance activities every 1000 operating hours Make sure that: q The diesel engine is in the maintenance position.

5.9.1 Checking that engine bearing and diesel engine console are securely seated u Check that the oil pan is firmly seated, tighten screws if necessary. u Check condition of diesel engine consoles and engine bearing and that they are firmly seated, tighten screws if necessary. (See: Repair manual)

5.9.2 Changing the fuel prefilter insert Make sure that: q A container with the required capacity is ready. q A replacement fuel prefilter insert is at hand.

The location of the fuel prefilter with water trap and manual fuel feed pump is removed from the diesel engine and the attachment method depends on the device design.

WARNING Naked flames!

Fire and explosion. u Avoid naked flames or lights when performing maintenance or inspection work on the fuel system. u Only perform maintenance and inspection work when the diesel engine has been shut down.

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If a fuel shut-off cock is present: u Close the fuel shut-off cock.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Operator's manual

Maintenance activities every 1000 operating hours

Fig. 78: Fuel prefilter u Place receptacle under the fuel prefilter. u Open shut-off cock. For procedure see chapter “Check / drain water trap on the fuel prefilter”. u Unscrew screws 2 and take off lid 3 with seal 4. u Take out fuel prefilter insert 5 along with spring cartridge 7. u Properly dispose fuel prefilter insert 5.

NOTICE Dirt!

Destruction of common rail system. u Make sure that no dirt gets onto the clean side of the filter. u Leave the residual diesel fuel in the filter housing. u Never reuse a fuel prefilter once used. u Note special instructions for working on the common rail system, see chapter “Safety instructions”. u Install new fuel prefilter insert 5. u Open fuel shut-off cock and vent fuel system. See the chapter “Venting fuel system” for procedure.

5.9.3 Changing the fuel fine filter Make sure that: q A container with the required capacity is ready. q Two fuel fine filters are at hand.

The fuel fine filters are located on the right as seen from the flywheel.

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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u Check seal 4, replace if necessary and assemble in reverse order.

Operator's manual

Maintenance Maintenance activities every 1000 operating hours

WARNING Naked flames!

Fire and explosion. u Avoid naked flames or lights when performing maintenance or inspection work on the fuel system. u Only perform maintenance and inspection work when the diesel engine has been shut down. u Place receptacle under the diesel engine. u Carefully clean the fuel fine filter and the surrounding area.

If a fuel shut-off cock is present: u Close the fuel shut-off cock.

Fig. 79: Fuel fine filter u Loosen the fuel fine filter 1 with strap spanner or similar tool and unscrew it.

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u Dispose of old fuel fine filter. (Observe country-specific regulations). u Check the filter base for cleanliness and make sure that the thread adapter is firmly seated in the filter base.

If the filter base is dirty: u Clean the filter base.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Maintenance

Operator's manual

Maintenance activities every 1000 operating hours

WARNING Dirt!

Destruction of common rail system! u Make sure that no dirt gets onto the clean side of the filter. u Never reuse a fuel fine filter once used. u Note special instructions for working on the common rail system, see chapter “Safety instructions”.

Fig. 80: Fuel fine filter u Lubricate the sealing ring 1 of the new fuel fine filter with clean oil.

NOTICE Damage to the common rail system due to dirt particles in the fuel. u Prevent any contamination, especially in the clean section of the fuel fine filter

u Screw on the fuel fine filter perpendicular to the bracket until the sealing ring is resting on the filter head. u Then tighten the fuel fine filter by hand 3/4 revolution. u Open fuel shut-off cock and vent fuel system. See the chapter “Venting fuel system” for procedure.

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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u Fuel filling of the fuel fine filter is prohibited.

Operator's manual

Maintenance Maintenance activities every 1500 operating hours

5.10 Maintenance activities every 1500 operating hours Make sure that: q The diesel engine is in the maintenance position.

5.10.1 Changing the diesel engine oil and oil filter The oil drain valve can be found on the diesel engine, at the bottom or at the side of the oil pan.

Make sure that: q The diesel engine is horizontal. q The diesel engine is turned off. q The diesel engine is warm. q Two original LIEBHERR oil filter cartridges are at hand. q A container with the required capacity is ready. q A suitable drain hose from the device manufacturer is available. q Diesel engine oil is at hand. For lubricant specification, see the chapter “Lubricants and operating fluids”.

Draining off diesel engine oil

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Fig. 81: Drain valve with drain hose CAUTION Hot engine oil!

Risk of burns. u Avoid skin contact with the engine oil. u When changing engine oil, wear protective gloves. u Unscrew the cap on the oil drain valve on the oil pan. u Screw the oil drain hose onto the oil drain valve. u Let oil drain into the container provided. u Dispose oil correctly. u Unscrew the oil drain hose and screw the closing cap onto the oil drain valve.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Maintenance activities every 1500 operating hours

Note u For diesel engines with integrated auxiliary outputs on the bottom of the flywheel housing, the drain plugs must be opened when changing the diesel engine oil.

Fig. 82: Flywheel housing with auxiliary outputs u Unscrew the two screw plugs. u Let oil drain into the container provided. u Screw in the screw plugs.

Note

Fig. 83: Oil pan (small sump) u Unscrew screw plug. u Let the oil (approx. 3 L) drain into the container provided. u Screw in the screw plug.

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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u For diesel engines with oil pan (small sump), the drain plug must be opened when changing the diesel engine oil.

Operator's manual

Maintenance Maintenance activities every 1500 operating hours

Replacing the oil filter The oil filters are attached upright on the diesel engine's unit support.

Make sure that: q A strap spanner or an Allen key WAF 30 as well as Original LIEBHERR oil filters (2 units) are at hand.

Fig. 84: Oil filter Note u Protect the V-ribbed belt against escaping oil when changing the oil filter. u After changing the oil filter, remove all oil spills on the diesel engine, including behind the vibration damper, so that they cannot subsequently be misdiagnosed as a leak in the rotary shaft lip seal. u Release the oil filter 1 with a strap spanner or Allen key WAF 30, and unscrew the filter.

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u Clean sealing surfaces of the filter bracket. w All filter seals and any remnants have been fully removed.

Fig. 85: Oil filter u Lightly coat the sealing ring 1 on the new oil filter with engine oil.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Operator's manual

Maintenance activities every 1500 operating hours

u Screw in the new oil filter until the sealing ring is resting on the filter bracket. w Sealing ring is resting on the filter bracket. u Tighten the oil filter 3/4 to 1 turn / 20 Nm- 5 Nm.

Filling the diesel engine oil

Fig. 86: Diesel engine oil filler neck u Fill the oil via the oil filler neck 1. u Do not replenish diesel engine with oil over the “max.” mark. u Clean filling cap, place on the filler neck and tighten. u Start the diesel engine and check oil pressure. u Turn off the diesel engine and check the oil level on the dipstick after 2 - 3 minutes.

Troubleshooting Oil level is not between the min. and max.? u Adjust the oil level.

Make sure that: q An oil separator filter insert is available.

The oil separator is fitted on the flywheel side, on the right side of the diesel engine.

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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5.10.2 Replacing the oil separator filter insert

Operator's manual

Maintenance Maintenance activities every 1500 operating hours

Fig. 87: Oil separator u Carefully clean the oil separator 1 and its surroundings. u Open and remove the oil separator cap 2; if necessary use a screwdriver. u Pull out the oil separator filter insert 3 and dispose of it in an environmentally friendly manner (observe country-specific regulations). u Install a new oil separator filter insert and push it in to the limit stop.

Note

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u Pay attention to the direction of the arrows on the cap and the housing!

Fig. 88: Oil separator - direction of arrows u Fit the oil separator cap 2 and tighten it by hand to the limit stop.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Maintenance

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Maintenance activities every 1500 operating hours

5.10.3 Checking and setting the valve clearance Make sure that: q A turning device special tool is available. See chapter “Special tools for maintenance activities”.

Note u Cylinder 1 is located on the flywheel side. u Direction of rotation as seen from the left side of flywheel u The outlet valve of the respective cylinder is located on the flywheel side.

Fig. 89: Cylinder valves A = Outlet valve E = Inlet valve Cylinder valves D934 / D944 Overlap

4

2

1

3

Set

1

3

4

2

Tab. 24: Cylinder valves D934 / D944

Overlap

6

2

4

1

5

3

Set

1

5

3

6

2

4

Tab. 25: Cylinder valves D936 / D946

Checking and setting the standard valve clearance u Remove cylinder head cover. u Mount turning device. u Turn crankshaft using the turning device in the direction of rotation until the valves belonging to the cylinders to be set overlap. For information, see tables “Cylinder valves D934 / D944” or “Cylinder valves D936 / D946”.

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Cylinder valves D936 / D946

Operator's manual

Maintenance Maintenance activities every 1500 operating hours

Fig. 90: Checking / setting inlet valve clearance

Fig. 91: Checking / setting outlet valve clearance u Slide feeler gauge between valve bridge and rocker arm and check valve clearance.

Troubleshooting Is the clearance not in agreement with the setting values (see chapter “Valve clearance technical data”)? u Unscrew lock nut on the adjusting screw of the respective rocker arm and correct setting. u Tighten lock nut with 45 Nm.

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u Check setting again. u After checking and/or setting all valves, install cylinder head cover with inspected, undamaged seals. u Dismantle turning device.

Checking and setting the valve clearance using engine auxiliary brake system (ABS) Checking and setting the inlet valve clearance u Remove cylinder head cover.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Maintenance activities every 1500 operating hours

u Mount turning device. u Turn crankshaft using the turning device in the direction of rotation until the valves belonging to the cylinders to be set overlap. For information, see tables “Cylinder valves D934 / D944” or “Cylinder valves D936 / D946”.

Fig. 92: Checking / setting inlet valve clearance u Slide feeler gauge between valve bridge and rocker arm and check valve clearance.

Troubleshooting Is the clearance not in agreement with the setting values (see chapter “Valve clearance technical data”)? u Unscrew lock nut on the adjusting screw of the respective rocker arm and correct setting. u Tighten lock nut with 45 Nm. u Check setting again. u After checking and/or setting all valves, install cylinder head cover with inspected, undamaged seals. u Dismantle turning device.

Fig. 93: Outlet valve bridge / rocker arm valve clearance u Slide feeler gauge between the outlet valve bridge and rocker arm adjusting screw and check valve clearance.

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Checking outlet valve clearance

Operator's manual

Maintenance Maintenance activities every 1500 operating hours

Troubleshooting Is the clearance not in agreement with the setting values (see chapter “Valve clearance technical data”)? u Set valve clearance.

Fig. 94: Outlet valve bridge / counterholder valve clearance u Slide feeler gauge between the outlet valve bridge and counterholder adjusting screw and check valve clearance.

Troubleshooting Is the clearance not in agreement with the setting values (see chapter “Valve clearance technical data”)? u Set valve clearance.

Setting outlet valve clearance

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Fig. 95: Outlet valve bridge / rocker arm valve clearance u Turn back adjusting screw 2 until the contact surface of the adjusting screw disappears into the counterholder. u Turn back adjusting screw 1 to the extent that the feeler gauge that corresponds to the setting value can be pushed in. u Turn in adjusting screw 1 until the piston in the outlet valve bridge arrives at the limit stop and the feeler gauge locks. u Untighten adjusting screw 1 until the feeler gauge can be pulled out against moderate resistance (suction). u Tighten adjusting screw 1 lock nut with 45 Nm. D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Maintenance

Operator's manual

Maintenance activities every 1500 operating hours

Fig. 96: Outlet valve bridge / counterholder valve clearance u Turn in adjusting screw 2, while a feeler gauge corresponding to the setting value is pushed in, until the piston of the valve bridge arrives at the limit stop and the feeler gauge locks. u Untighten adjusting screw 2 until the feeler gauge can be pulled out against moderate resistance (suction). u Tighten adjusting screw 2 lock nut with 45 Nm. w Push rod must have play. u Check settings again. u After checking and/or setting all valves, install cylinder head cover with inspected, undamaged seals.

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u Dismantle turning device.

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

Operator's manual

Maintenance Maintenance activities every 2000 operating hours

5.11 Maintenance activities every 2000 operating hours Make sure that: q The diesel engine is in the maintenance position.

5.11.1 Checking the corrosion frost protection agent concentration in the coolant The coolant must contain at least 50 vol. %, but not more than 60 vol. %, of corrosion frost protection agent year-round. A coolant with 50 vol. % corrosion frost protection agent corresponds to an antifreeze protection up to approx. -37 °C.

Checking the corrosion frost protection agent concentration DANGER Hot coolant!

Risk of burns. u Let engine cool off before opening the filler neck. u Carefully open the cap on the filler neck. u Take coolant sample and analyse using an appropriate test method.

If the analysis results in too low frost protection: u Adjust the mixing ratio of the corrosion frost protection agent in the coolant.

Correcting the corrosion frost protection agent concentration

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If the corrosion frost protection agent concentration is too low: u Drain coolant and refill corrosion frost protection agent according to the calculation formula below.

Coolant content (total)

=

50 litres

Measured concentration

=

29 vol. %

↓

↓

↓

→

50

-

29

=

21

100

-

29

=

71

↓

x

50 →

Corrosion frost protection agent refilling quantity: :

71 ↑

=

14.8 litres This amount must normally be drained beforehand!

Tab. 26: Corrosion frost protection agent refilling quantity calculation formula, example 29 vol. % (corresponds to -15 °C)

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Maintenance activities every 2000 operating hours

NOTICE Amount of corrosion frost protection agent in coolant too high!

Diesel engine overheats and may be damaged. u Do not use more than 60% corrosion frost protection agent.

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u See documentation from the device manufacturer for coolant fill quantity.

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

Operator's manual

Maintenance Maintenance activities every 5000 operating hours

5.12 Maintenance activities every 5000 operating hours Make sure that: q The diesel engine is in the maintenance position.

5.12.1 Replacing the belt drive Replacing the V-ribbed belt Make sure that: q A new V-ribbed belt is at hand. q A ratchet DIN 3122 D 12.5 (1/2') is at hand.

WARNING Rotating components! u Shut down the diesel engine. u Be aware of the run-down time; before opening the covers, make sure that no parts are still moving.

Fig. 97: V-ribbed belt for alternator drive with A/C compressor u Pivot back the tensioning device in an anticlockwise direction against the spring force to the limit stop.

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u Remove the V-ribbed belt.

Troubleshooting Do you notice any damage? u Replace the damaged parts.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Maintenance

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Maintenance activities every 5000 operating hours

Fig. 98: V-ribbed belt run - variants 1

Crankshaft belt pulley

4

2 3

Alternator belt pulley Tensioning device

5 6

Air conditioning compressor belt pulley Deflection roller Water pump belt pulley

u With the tensioning device pivoted back, place new V-ribbed belt on the belt pulleys of the crankshaft, air conditioning compressor, alternator and deflection roller. u Fit V-ribbed belt guard (optional).

Changing the deflection rollers and tensioning device

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u For the procedure, see the repair manual

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Operator's manual

Maintenance Maintenance activities every 6000 operating hours

5.13 Maintenance activities every 6000 operating hours Make sure that: q The diesel engine is in the maintenance position.

5.13.1 Replacing the coolant Make sure that: q Heating valves, if present, are open. q A container with the required capacity is ready. q A drain hose is at hand. q The required quantity of coolant is at hand.

Draining the coolant in the diesel engine DANGER Hot cooler fluid!

Risk of burns. u Let engine cool off before opening the coolant equalising reservoir. u Note overpressure when opening the coolant equalising reservoir. u Do not fill the cooling system when the engine is hot under any circumstances.

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Fig. 99

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Maintenance

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Maintenance activities every 6000 operating hours

Fig. 100: Coolant drain valve u Place receptacle under the diesel engine. u Turn closing cap on the coolant equalising reservoir until the overpressure is released, then open it. See documentation from the device manufacturer.

CAUTION Coolant can cause injuries to the eyes and allergic skin reactions! u You must avoid skin contact with coolant. u Note manufacturer instructions. u Immediately irrigate eye or skin splashes with water. u Open protecting cap on the drain valve 1. u Screw drain hose onto drain valve 1. w The drain valve is opened while doing so. Coolant flows into the container.

When the coolant has drained: u Unscrew the drain hose from the drain valve 1. u Screw on protecting cap.

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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u Wear rubber gloves and protective glasses when mixing coolants.

Operator's manual

Maintenance Maintenance activities every 6000 operating hours

Filling the coolant

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u See documentation from the device manufacturer for procedure.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Maintenance activities every 10000 operating hours

5.14 Maintenance activities every 10000 operating hours Make sure that: q The diesel engine is in the maintenance position.

5.14.1 Replacing the heating flange Make sure that: q A new heating flange is available.

The heating flange is installed on the right side of the diesel engine or in the air intake pipe.

Fig. 101: Removing and installing the heating flange u If present, turn off the battery master switch and detach the minus cable from the battery. u Detach electrical connecting cables from the heating flange. u Install new heating flange. u Connect electrical connecting cables to the heating flange and the minus cable to the battery.

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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u Remove heating flange.

Operator's manual

Maintenance Occasional maintenance activities

5.15 Occasional maintenance activities

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Make sure that: q The diesel engine is in the maintenance position.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Maintenance

Operator's manual

Checking the heating flange

5.16 Checking the heating flange Make sure that: q A ohmmeter and multimeter is available.

The heating flange (1) is installed on the right side of the diesel engine or in the air intake pipe.

Fig. 102: Heating flange u If present, turn off the battery master switch and detach the minus cable from the battery. u Detach electrical connecting cables from the heating flange. u Connect the ohmmeter or multimeter to the terminals and measure resistance.

Troubleshooting Is a resistance of 250 mOhm +/- 10 % at 20 C not achieved?

u Connect electrical cables to heating flange and minus cable to the battery.

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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u Replace heating flange.

Operator's manual

Maintenance Venting the fuel system

5.17 Venting the fuel system Venting of the fuel prefilter and fuel low pressure system is required after: q changing the fuel prefilter q running the fuel tank dry q initial commissioning of the diesel engine WARNING Dirt!

Destruction of common rail system. u No injection lines nay be opened or detached. u Ensure complete cleanliness for all work. u Note special instructions for working on the common rail system, see chapter “Safety instructions”.

WARNING Naked flames!

Fire and explosion. u Avoid naked flames or lights when performing maintenance or inspection work on the fuel system. u Only perform maintenance and inspection work when the diesel engine has been shut down.

NOTICE If the venting screw on the fuel prefilter is open, then the system will not be vented properly.

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u Do not open the venting screw on the fuel prefilter.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Maintenance

Operator's manual

Venting the fuel system

Fig. 103: Manual feed pump u Turn the “PUMP” mark 2a in the direction of the arrow (clockwise). u Actuate the manual feed pump 2b. u Keep actuating the manual pump until a strong resistance is felt.

In order to start the diesel engine: u Turn the “RUN” mark 2c in the direction of the arrow (anticlockwise). u Start diesel engine.

Troubleshooting If the starting procedure is still unsuccessful after approx. 20 seconds: u Take a break for 1 minute.

If you have repeated this procedure three times without success: u Repeat air venting procedure.

u Low pressure circuit (NDK) of the motor is vented by permanently installed restrictor bores; no additional measures are necessary.

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Note

Operator's manual

Maintenance Replacing the dry air filter main element

5.18 Replacing the dry air filter main element

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For procedure for replacing dry air filter main element, see documentation from the device manufacturer.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Maintenance

Operator's manual

Replacing the dry air filter safety element

5.19 Replacing the dry air filter safety element

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For procedure for replacing dry air filter safety element, see documentation from the device manufacturer.

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

Operator's manual

Maintenance Transport and storage

5.20 Transport and storage 5.20.1 Suspension device DANGER Falling load!

Danger to life. u Observe maximum weight for lifting points! u Observe a maximum of a 10° deviation from vertical to the engine axis! u Use Liebherr lifting traverse! u Only use transport equipment to transport the engine with no additional attachments! u Take into account safety instructions / warning signs from the operating instructions of the lifting traverse!

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u Do not work under suspended loads!

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Transport and storage

Fig. 104: Suspension device A

Detailed view of transport device Front/rear view with two transport devices on the side

E

C

Engine viewed from the side

1

D

Front/rear view with one transport device on the side

2

F

3

Lifting traverse

4

Lifting point for engine with lifting traverse (observe the maximum total load)

5

Tolerance for maximum deviation from the horizontal

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B

Detailed view of lifting point on the lifting traverse Warning sign on the lifting traverse, observe the lifting traverse's operating instructions.

Tolerance for maximum deviation to engine axle.

Engine block

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

Operator's manual

Maintenance Transport and storage

Fig. 105: Suspension device Note Lifting traverse ID no. 10815480 u Before commissioning the lifting traverse, read and observe the safety instructions in the system description.

5.20.2 Storage up to 6 months The LIEBHERR diesel engine is preserved from the shipping date; under normal storage conditions in a dry, well ventilated place, the normal conservation protection duration is 6 months.

If the diesel engine is covered with a film cover, it can also be stored outdoors for up to one month.

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The cover must be waterproof and loosely rest against the diesel engine so that air can circulate around the diesel engine and so that the formation of condensation is prevented.

A shorter conservation protection period is to be expected in case of departure from the measures mentioned, whereby the conserved diesel engine is exposed to less favourable conditions (situated outdoors for longer periods of time or storage in damp, unventilated locations etc.).

5.20.3 Storage over 6 months up to 24 months For storage over 6 months up to 24 months, contact LIEBHERR Service or an authorised LIEBHERR dealer.

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Maintenance

Operator's manual

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Transport and storage

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

6 Supplemental information for the USA

Additional information for the United States Environmental Protection Agency (mentioned in the following “EPA”) and the California Air Resources Board (mentioned in the following “CARB”).

6.2.1 EPA/CARB fuel label The engine must be operated with “ULTRA LOW SULFUR FUEL ONLY”.

Within the proximity of the filler neck the following label with the remark “ULTRA LOW SULFUR FUEL ONLY” must be attached in a such way that it is well visible and permanently readable when refuelling.

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Fig. 106: Fuel label “ULTRA LOW SULFUR FUEL ONLY” 10315343

D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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Operator's manual

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Supplemental information for the USA

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

Index

Coolant thermostat 15 Cooling system 49 Correcting the corrosion frost protection agent concentration 81 Corrosion frost protection agent 53 Crushing 20 Cylinder designation, direction of rotation 13 Cylinder head with engine auxiliary brake system (ABS) 14

A

D

Additional identifications 18 Air filter 49 Alternator 15

B Burns and scalds 20

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C Changing the deflection rollers and tensioning device 84 Changing the diesel engine oil and oil filter 71 Changing the fuel fine filter 68 Changing the fuel prefilter insert 67 Check / set valve clearance. 48 Check condition of control unit bearings 65 Check condition of sensors, actuators, cable holders and plugs 66 Check cooling and heating system for condition and leaks 65 Checking and setting the inlet valve clearance 77 Checking and setting the standard valve clearance 76 Checking and setting the valve clearance 76 Checking and setting the valve clearance using engine auxiliary brake system (ABS) 77 Checking outlet valve clearance 78 Checking state of belt drive and replacing, if necessary 64 Checking that engine bearing and diesel engine console are securely seated 67 Checking the batteries and cable connections 65 Checking the coolant level 59 Checking the corrosion frost protection agent concentration 81 Checking the corrosion frost protection agent concentration in the coolant 81 Checking the engine oil level 58 Checking the heating flange 90 Checking the intake and exhaust system for condition and leaks 64 Checking the lubricant and fuel system for condition and leaks 65 Checking the underpressure display of the air filter 61 Checking / draining water trap on the fuel prefilter 59 Clean the dust extraction valve of the air filter 62 Coolant 53 D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

Danger due to noise 22 Design overview 9 Diesel engine 14, 48 Diesel engine type plate 11 Diesel fuels 51 Disposal 39 Disposal of operating fluids 27 Draining fuel prefilter 60 Draining off diesel engine oil 71 Draining the coolant in the diesel engine 85 Draining water and sediments from the fuel tank 62

E Electrical energy 21 Electrical system 49 Emergency stop 25 Engine control unit type plate 12 Engine oils 51 EPA/CARB fuel label 99 EU strategies (Stage IV) / US-EPA/CARB (Tier4) 31 Exhaust after-treatment system 38, 49 Exhaust after-treatment system (SCR) 28 Exhaust after-treatment system indicator and warning lamps 29 Explanation of type designation 10

F Faults - Cause - Remedy 41 Fill quantities 50 Filling the coolant 87 Filling the diesel engine oil 74 Fires and explosions 21 Flywheel housing 15 Fuel system 49

G General safety instructions 19

H High-pressure injection (fluids spraying out under high pressure) 21

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Index

Operator's manual

I

R

Identification of the warnings 17 Index 101 Indicator and warning lamps 29 Inspecting the exhaust after-treatment system profile clips 62 Intended use 18

Reducing agent 51 Replace diesel engine oil (at least every 2 years). 48 Replace oil filter (at least every 2 years). 48 Replace the oil separator filter insert. 48 Replacing the belt drive 83 Replacing the coolant 85 Replacing the dry air filter main element 93 Replacing the dry air filter safety element 94 Replacing the heating flange 88 Replacing the oil filter 73 Replacing the oil separator filter insert 74 Replacing the V-ribbed belt 83

Liebherr recommendation 53 Liebherr recommends for engines without emission type approval 52 Liebherr recommends for Stage IV / Tier 4 diesel engines 51 Limitation of liability 19 Lubricants and operating fluids 50, 51 Lubricating oil change intervals for engine oils with Liebherr approval 51, 52

M

S Safety instructions 17, 23, 38 Securing and releasing the diesel engine against unexpected start-up 25 Setting outlet valve clearance 79 Shutting off the engine 37 Signage 25 Special tools for maintenance activities 54 Standard cylinder head 14 Starter 15 Starting the engine 35, 35 Storage over 6 months up to 24 months 97 Storage up to 6 months 97 Supplemental information for the USA 99 Suspension device 95

Maintenance 47 Maintenance activities (daily) every 10 operating hours 58 Maintenance activities every 1000 operating hours 67 Maintenance activities every 10000 operating hours 88 Maintenance activities every 1500 operating hours 71 Maintenance activities every 2000 operating hours 81 Maintenance activities every 50 operating hours (weekly) 62 Maintenance activities every 500 operating hours 64 Maintenance activities every 5000 operating hours 83 Maintenance activities every 6000 operating hours 85 Maintenance and inspection schedule 47 Maintenance areas 24 Minimum quality requirements 51, 53

Target group 18 Technical data 14 Technical description 9 Transport and storage 95 Type designation 10

O

U

Occasional maintenance activities 89 Operating areas 23 Operating areas and maintenance areas 23 Operating faults 41 Operation 29

Unauthorised personnel 18

P Personal protective equipment 22 Poisoning 21 Preceding work for the initial commissioning of the engine 35 Preparatory maintenance activities 57 Preventing personal injuries 20 Preventing property damage 26 Product description 9

T

V Venting the fuel prefilter 61 Venting the fuel system 91 Visual inspection (leaks, contaminations, damage) 58 Visual inspection of exhaust after-treatment system 61

W Warning and malfunction strategies 29 Water 53

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D934 A7–04 / D944 A7–04 / D936 A7–04 / D946 A7–04 / D934 A7–00 / D944 A7–00 / D936 A7–00 / D946 A7–00 / 2014030001 / 2014040001

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