Description

Liebherr D934 A7 SCR, D936 A7 SCR, D946 A7 SCR Engine Service Manual

Engine Applicable Model : D934 A7 SCR, D936 A7 SCR, D946 A7 SCR
Language: English
Publication number: 11160830
Format: PDF
April 2012

Liebherr D934 A7 SCR, D936 A7 SCR, D946 A7 SCR Engine Service Manual – 102 Pages

Table of Content of the Service Manual:

Target group
This repair manual has been compiled specifically for the mechanics and the workshop personnel of the LIEBHERR Owners and LIEBHERR subsidiaries, whose task it is to ensure that the diesel engines are in perfect working order.

Contents
This repair manual provides you with technical documentation regarding the installation and removal, disassembly and assembly, adjustment tasks and technical data for Liebherr diesel engines.
1 General information………………………………………………………………………………………………………………… 1-9
1.1 Structure of this manual………………………………………………………………………………………………….. 1-12
1.2 Important notes within this manual …………………………………………………………………………………… 1-14
1.2.1 Designation of activity-related notes on safety………………………………………………………. 1-14
1.2.2 Further designations………………………………………………………………………………………….. 1-14
1.3 Symbols in this manual…………………………………………………………………………………………………… 1-15
1.4 Notes on safety……………………………………………………………………………………………………………… 1-16
1.4.1 General notes on safety …………………………………………………………………………………….. 1-16
1.4.2 Preventing injury to persons……………………………………………………………………………….. 1-17
1.4.3 Preventing damage to property …………………………………………………………………………… 1-19
1.5 Notes regarding working on the fuel system and injection system………………………………………… 1-21
1.5.1 General notes on safety …………………………………………………………………………………….. 1-21
1.5.2 Preventing injury to persons……………………………………………………………………………….. 1-21
1.5.3 Preventing damage to property …………………………………………………………………………… 1-21
1.6 Notes on safety for working on the exhaust after-treatment system (SCR system) …………………. 1-23
1.6.1 Carbamide solution …………………………………………………………………………………………… 1-23
1.6.2 General notes on safety …………………………………………………………………………………….. 1-23
1.6.3 Preventing injury to persons……………………………………………………………………………….. 1-23
1.6.4 Preventing damage to property …………………………………………………………………………… 1-24
1.7 Technical Data………………………………………………………………………………………………………………. 1-25
1.7.1 Engine in general ……………………………………………………………………………………………… 1-25
1.7.2 Standard tightening torques for screw connections ……………………………………………….. 1-30
1.7.3 Standard torques for locking screws and banjo bolts……………………………………………… 1-32
1.7.4 Standard torques for metric threaded unions………………………………………………………… 1-33
1.7.5 Standard torques for imperial threaded unions ……………………………………………………… 1-35
1.7.6 Standard torques for cutting ring threaded unions …………………………………………………. 1-37
1.7.7 Standard torques for Triple Lock threaded unions …………………………………………………. 1-38
1.7.8 Standard torques for VSTI screw plugs………………………………………………………………… 1-39
1.7.9 Special torques, tightening specifications, installation specifications and
installation instructions ………………………………………………………………………………………. 1-40
General notes……………………………………………………………………………………………… 1-40
Tightening specification for main bearing………………………………………………………… 1-40
Tightening specification for aggregate carrier ………………………………………………….. 1-40
Tightening specification for piston cooling nozzle …………………………………………….. 1-41
Tightening specification for final regulating valve and cold start valve…………………. 1-41
Tightening specification for oil intake ……………………………………………………………… 1-41
Tightening specification for oil drain valve ………………………………………………………. 1-41
Tightening specification for oil sump (D934) ……………………………………………………. 1-42
Tightening specification for oil sump (D936 / D946)………………………………………….. 1-43
Tightening specification for crankshaft accessories ………………………………………….. 1-44
Tightening specification for connecting rod ……………………………………………………… 1-44
Tightening specification for cylinder head ……………………………………………………….. 1-45
Installation and tightening specification for counterbalancing shafts (D934)…………. 1-46
Tightening specification for rocker arm support ……………………………………………….. 1-48
Installation and tightening specification for cam shaft ……………………………………….. 1-49
Tightening specification for oil cooler ……………………………………………………………… 1-51
Tightening specification for oil cooler housing (D934)……………………………………….. 1-51
Tightening specification for oil cooler housing (D936 / D946) …………………………….. 1-51
Tightening specification for fitting in oil filter bracket …………………………………………. 1-51
Installation and tightening specification for high-pressure pump…………………………. 1-52
Installation and tightening specification for injector and pressure pipe tube …………. 1-54
Installation instruction for cable harness on injector………………………………………….. 1-56
Tightening specification for sensors ……………………………………………………………….. 1-57
Installation instruction for cable harness …………………………………………………………. 1-59
Installation instruction for throttle valve …………………………………………………………… 1-60
Tightening specification for heater flange………………………………………………………… 1-60
Tightening specification for idler…………………………………………………………………….. 1-60
Tightening specification for air compressor gear………………………………………………. 1-60
Installation instruction for coolant pump ………………………………………………………….. 1-61
Tightening specification for exhaust manifold (D934) ……………………………………….. 1-62
Tightening specification for thermal protection plate (D934) ………………………………. 1-62
Tightening specification for exhaust manifold (D936 / D946)……………………………… 1-62
Tightening specification for thermal protection plate (D936 / D946) ……………………. 1-62
Tightening specification for coolant pump ……………………………………………………….. 1-63
Tightening specification for turbocharger and flange on turbocharger …………………. 1-63
Tightening specification for generator belt pulley ……………………………………………… 1-64
Tightening specification for flywheel housing …………………………………………………… 1-64
Tightening specification for flywheel……………………………………………………………….. 1-65
Tightening specification for control unit-mount…………………………………………………. 1-66
Tightening specification for power take-off………………………………………………………. 1-66
Tightening specification for SCR module (installed machine side) ……………………… 1-67
1.7.10 Cleaning agents, thread-locking adhesives and greases………………………………………… 1-69
1.8 Representations of the engine and engine components ……………………………………………………… 1-70
1.8.1 Gear train (D934)………………………………………………………………………………………………. 1-70
1.8.2 Gear train (D936 / D946)……………………………………………………………………………………. 1-71
1.9 Diagram of the fuel system ……………………………………………………………………………………………… 1-72
1.9.1 Representation of overall system ………………………………………………………………………… 1-74
1.10 Diagram of lube oil system ……………………………………………………………………………………………… 1-76
1.11 Diagram of coolant system ……………………………………………………………………………………………… 1-78
1.12 Allocation of ducts in the crankcase and in the cylinder head ………………………………………………. 1-80
1.13 Tools ……………………………………………………………………………………………………………………………. 1-81
1.13.1 Special tools …………………………………………………………………………………………………….. 1-81
Lifting beam………………………………………………………………………………………………… 1-81
Engine assembly stand ………………………………………………………………………………… 1-85
Lifting device for flywheels (SAE0, SAE1 and SAE2) ……………………………………….. 1-90
Turning gears ……………………………………………………………………………………………… 1-92
Mounting bolts…………………………………………………………………………………………….. 1-96
Angle of rotation devices………………………………………………………………………………. 1-96
Torx tools …………………………………………………………………………………………………… 1-97
Installing and dismantling the cylinder liner……………………………………………………… 1-98
Checking excess length of the cylinder liners ………………………………………………….. 1-99
Installing and dismantling the front crankshaft seal ………………………………………….. 1-99
Installing and dismantling the crankshaft ………………………………………………………. 1-100
Installing and dismantling the piston with connecting rod and piston rings…………. 1-100
Installing and dismantling the piston rings …………………………………………………….. 1-100
Installing and dismantling valve stem seals, valve springs and valves ………………. 1-100
Installing and dismantling the counterbalancing shafts……………………………………. 1-101
Dismantling and installing the camshafts ………………………………………………………. 1-101
Installing and dismantling the injection lines ………………………………………………….. 1-101
Installing and dismantling the pressure pipe tube and injector …………………………. 1-101
Installing and dismantling the flywheel………………………………………………………….. 1-102
Installing and dismantling the rear crankshaft seal …………………………………………. 1-102

Notes on safety
The accident-prevention guidelines and all generally recognised safety-technical and occupational-medicinal regulations are to be observed before commencing any maintenance and repair tasks on Liebherr diesel engines. National guidelines applicable for the respective country of use and/or for the application site must be observed wherever necessary.
Furthermore, the notes on safety regarding diesel engines in the chapter “Notes on Safety” are to be observed.