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  • Liebherr D9812; Twelve-Cylinders of Mining Might

Liebherr D9812; Twelve-Cylinders of Mining Might

Twelve Cylinders of Diesel Might Designed to Conquer Mining’s Harsh Environment

John Lehenbauer
Apr 11, 2018
Photographers: Courtesy of Manufacturer
Mining equipment, dump trucks, and hydraulic excavators perform in some of the harshest working environments a vehicle can endure. The heavy workloads and dusty conditions in the mines can cause the early demise of mechanical components. Anything expected to last must be designed to handle severe elements.
It’s essential that dirt and water be kept out of engines in these machines, as any amount of dust—no matter how slight—drawn in can shorten their lives significantly. However, very fine particles like silt and sand are able to find minute openings. For this reason, it is important to ensure a powerplant is sealed properly from all foreign matter.
Liebherr understands the consequences of damaging particles making their way into any closed mechanical system. So, when the company developed the D9812 62L V-12 diesel engine for mining applications, one of its main focuses was preventing foreign contaminants from entering the intake or crankcase. If an engine’s internals are kept clean, it will be more reliable and have a long, productive service life. A high level of detail is used during assembly of Liebherr’s V-12 diesel to guarantee the quality of the engine’s sealed joints and gaskets and ensure they withstand the brutal conditions in the mines. Some of the more critical components are installed with double seals to make sure nothing can enter.
A very high level of oil and air filtration is implemented in the D9812 62L, for example, the use of a centrifuge that spins the oil to separate dirt.
Dirt in the crankcase is such a major concern that special materials like composite bearing shells are used so that components are less sensitive to oil contamination and heavy loads. Water and dirt infiltration is also addressed in the wiring harness. The engine’s electrical connectors meet the protection standard IP6k9k [Ingress Protection (IP) rating system relates to the proven protection against environmental factors such as liquids and solids], which guarantees they are water-, dust-, and arctic-weatherproof.
Photo 2/2   |   The modular design of the Liebherr D9812 makes the engine easily configurable for different applications. The engine is capable of enduring environmental challenges like arctic cold, high altitude, and hot, arrid conditions.
As with most modern diesel powerplants, an engine control unit coordinates all of D9812’s functions for peak emissions and fuel-consumption efficiency. It also features advanced diagnostic software. One of the key components the ECU manages is the Liebherr common-rail 11.5 fuel-injection system. The engine’s fueling operates at pressures up to 2,200 bar with a multipoint injection (multiple injections per piston cycle) that helps optimize performance and lower fuel consumption, emissions, and combustion noise by precisely controlling the amount of fuel being administered and the timing of each injection event.
The D9812’s modular composition allows the engine to be easily tailored to fit different vehicle applications for use and optimum performance in varying climates and conditions of regions all over the world. Modular components also simplify repairs by making such parts as the turbochargers, cylinder heads, and exhaust-gas-aftertreatment systems easily interchangeable.
Internally, D9812 is 3-D measured (for production accuracy), fitted with one-piece steel pistons (for maximum strength under thermo load) and connecting rods with a finite element analysis (computerized method for predicting how a product reacts to real-world forces like vibration, heat, and fluid flow), and has an ability to run at a reduced speeds. By lowering the rated speed of operation from 1,800 rpm to 1,500 rpm, a 20 percent increase in engine life is possible and up to a 5 percent fuel savings can be seen without any loss in productivity.
Engine: Liebherr D9812
Displacement: 62L (3784 ci)
Engine Layout: V-12
Valvetrain: Two valves
Bore x Stroke: 6.89 x 8.46 inches (175 x 215 mm)
Compression Ratio: 17.5:1
Head material: Cast iron
Block material: Cast iron
Piston material: Steel
Power: 3,621 hp (2,700 kw)
Torque: 11,572 lb-ft (15,690 Nm)
Emissions: EPA Tier 4 Final and EU Stage V
Induction: Two modular turbochargers
Exhaust: Cast-iron manifolds
Cooling System: Liquid-cooled
Intercooler: Dual air-to-water
Fuel System: Common-rail 11.5 fuel injection
Lubrication System: Wet sump
Lubrication Capacity: 254 quarts (240 liters)
Dry Weight: 18,960 pounds (8,600 kilograms)
Length: 104.8 inches (2,661 mm)
Width: 70 inches (1,777 mm)
Height: 83.7 inches (2,125 mm)


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