Liebherr D924t-e D924ti-e, D926t-e D926ti-e Diesel Engine Complete Workshop Service Repair Manual

Administrator X4IQAT1XJQSU1TP printed this protected Document 'D904_D906_D914_D916_D924_D926_ 8718458_04092008_v02_en.pdf' Friday, 01.January 2010 19:59

Foreword This manual includes the major points for proper maintenance, adjustments and repairs with technical data and screw tightening torques for Liebherr Diesel engine D 904 / 906 / 914 / 916 / 924 / 926. These tasks must be carried out by trained professionals. The Service manual will not be updated. For that reason, we always refer to additional Service Information bulletins. All changes will be incorporated when the Service manual is reissued periodically. No part of this documentation may be reproduced or copied without our explicit written permission. This Service manual was written by Liebherr-Machines-Bulle S.A., Dept. Service – Diesel - Engine and issued by the Service Dept., Liebherr Hydraulikbagger GmbH, Kirchdorf/Iller, Dept. VS. All changes reserved. LIEBHERR-MACHINES-BULLE SA All rights reserved. Dept.: Service – Diesel – Engine Issue: Id. No. 12 / 2003 8718458 (English) Administrator X4IQAT1XJQSU1TP printed this protected Document 'D904_D906_D914_D916_D924_D926_ 8718458_04092008_v02_en.pdf' Friday, 01.January 2010 19:59

Index 1) Engine illustrations 2) Technical description 3) Engine description, engine data tag, cylinder description, direction of rotation and engine identification number 4) Engine data, adjustment values, operating pressures, operating temperatures and fluid quantities 5) Torque specifications 6) Valve adjustment 7) Cylinder head gaskets 8) Cylinder head 9) Cylinder liner 10) Piston and connecting rod 11) Check piston clearance 12) Crankshaft an bearing 13) Camshaft and valve drive 14) Lubrication circuit 15) Oil pans 16) Lube oil pump 17) Lube oil filter and oil cooler 18) Coolant circuit 19) Water filter 20) Coolant pump 21) Fan drive 22) Fuel system 23) Fuel pump 24) Fuel filter 25) Injection pump 26) Injection pump drive, adjust begin of delivery 27) Fuel injector 28) Engine exhaust 29) Fan and flywheel side crankshaft seal 30) Hydraulic pump auxiliary drive 31) Air compressor 32) Starter 33) Air conditioner compressor and alternator 34) Starting aid 35) Turbo charger 36) Gear drive 37) Maintenance and inspection 38) Service fluids 39) Troubleshooting 40) Special tools Administrator X4IQAT1XJQSU1TP printed this protected Document 'D904_D906_D914_D916_D924_D926_ 8718458_04092008_v02_en.pdf' Friday, 01.January 2010 19:59

1 Engine illustrations Engine view: Left , as seen from the flywheel side onto the engine 1 Air compressor 2 Oil separator 3 V-belt - crankshaft 4 Coolant temperature sensor 5 Oil pressure sensor (with warning contact) 6 Starter 7 Coolant pump 8 Fan 9 Alternator 10 Coolant thermostat 11 Exhaust turbocharger 12 Water filter 13 Air conditioner compressor Engine view: Right, as seen from the flywheel side onto the engine 14 Oil dipstick 15 Valve cover 16 Oil filter 17 Injection pump 18 Oil filler neck 19 Suction pipe 20 Fuel filter 21 Fuel pump 22 Solenoid valve (flame glow plug) 23 Flame glow plug 24 Data tag 25 Hydraulic pump auxiliary drive Administrator X4IQAT1XJQSU1TP printed this protected Document 'D904_D906_D914_D916_D924_D926_ 8718458_04092008_v02_en.pdf' Friday, 01.January 2010 19:59

MJFCIFSS Datum / Edition / Date 12 / 2003 Benennung / Description / Denomination Typ Model Type Blatt Page Feuille Engine illustration D 904 / 914 / 924 D 906 / 916 / 926 1 Administrator X4IQAT1XJQSU1TP printed this protected Document 'D904_D906_D914_D916_D924_D926_ 8718458_04092008_v02_en.pdf' Friday, 01.January 2010 19:59

2 Technical description Engine design Water-cooled, 4 and 6 cylinder in-line engines with LIEBHERR direct injection process and exhaust turbocharger. Characteristics A sturdy basic construction and generous dimensions provide the foundation for high operating safety and long service life. Low fuel consumption, low noise and exhaust emissions are achieved through a combustion process, which is specially adapted to requirements. Low maintenance effort on easily accessible components and a variety of optional accessories ensure good overall efficiency. Power transmission The 4 cylinder engines feature a steel crankshaft with 5 bearings, the 6 cylinder engines 7 bearings, with inductively hardened bearing surfaces and 8 / 12 forged counterweights. A vibration damper is installed on the fan side on the crankshaft. Forge-pressed, split connecting rod, leaded bronze tri-metal sliding bearings or sputter bearings, smooth shaft three ring piston of aluminum alloy with ring support and combustion recess in the piston base. Exchangeable, wet cylinder liners Housing The crankcase is made in one unit of alloy cast iron. Single cylinder heads with integrated intake channel and removable / exchangeable valve seat rings and valve guides. Flywheel housing, front timing case and oil pan on the underside close off the engine. Engine timing Per cylinder one intake and exhaust valve each, suspended in the cylinder head (ohv.). Actuated by a steel camshaft with 5 or 7 bearings via steel tappets, push rod and rocker arm. Drive of camshaft, injection pump, lube oil pump, air compressor, coolant pump, and auxiliary hydraulic pumps by the crankshaft via nitride gears on the fan side. Lubrication Force-feed lubrication with gear pump for crankshaft, connecting rod and camshaft bearings as well as piston pin bushing, tappet and rocker arm. Oil filtration via two replaceable filter elements in the main oil circuit. Auxiliary components as well as injection pump and air compressor are connected to engine lubrication circuit. The engine oil cooler is integrated in the coolant flow. Cooling Dual thermostatically regulated fluid cooling with rotary pump. Individual supply of each cylinder unit via distributor channels integrated in the crankcase. Piston cooling through oil spray from engine lubrication circuit. Fuel injection system and regulation Maintenance free BOSCH in line injection pump or distributor pump with mechanical BOSCH centrifugal regulator. On A4, A5 - engines with „EDC“ control (electronic regulation), fuel pump with fuel filter, BOSCH four or six hole nozzles. Administrator X4IQAT1XJQSU1TP printed this protected Document 'D904_D906_D914_D916_D924_D926_ 8718458_04092008_v02_en.pdf' Friday, 01.January 2010 19:59

Flame starter The flame starter is a cold starting assistance for low ambient temperature. It minimizes the emission of white smoke after starting the diesel engine. By reducing the starting period, the starter and the batteries will be saved. The flame spark plug, mounted in the air intake, will get fuel via a solenoid valve with dosaging nozzle and could set free. Electrical equipment Starter and alternator: 24 Volt Electronic sensors controlling the engine parameters Air charge pressure sensor, temperature sensor at cooling agent and air charge, rotation sensor and oil pressure sensor are indicators for the external control functions. Each function and error signal is described in the corresponding user manual. MJFCIFSS Datum / Edition / Date 12 / 2003 Benennung / Description / Denomination Typ Model Type Blatt Page Feuille Technical description D 904 / 914 / 924 D 906 / 916 / 926 2 Administrator X4IQAT1XJQSU1TP printed this protected Document 'D904_D906_D914_D916_D924_D926_ 8718458_04092008_v02_en.pdf' Friday, 01.January 2010 19:59

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Liebherr D924t-e D924ti-e, D926t-e D926ti-e Diesel Engine Complete Workshop Service Repair Manual

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