Liebherr D856 Diesel Engine Operating Instruction Manual – PDF DOWNLOAD

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Liebherr D856 Diesel Engine Operating Instruction Manual – PDF DOWNLOAD

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Liebherr D856 Diesel Engine Operating Instruction Manual – PDF DOWNLOAD

Language : English
Pages : 126
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Liebherr D856 Diesel Engine Operating Instruction Manual – PDF DOWNLOAD

Foreword:
1.1 Information on the Operating Instruction:

• This operating instruction provides important information on the handling of engines. The prerequisite for
  safe working is the observance of all safety warnings and handling instructions.
  Furthermore, the local accident prevention regulations valid for the engine’s area of application and the
  general safety regulations must be observed.
• Timely and proper maintenance and care of the engines according to the set maintenance intervals ensure
  and maintain the operational safety and the reliable application of these engines.
• Use exclusively original Liebherr, or Liebherr-approved spares and accessories.
  Only original spare parts we have approved have been tested by us and therefore satisfy the requirements
  for use on the engine.
• A special concern of Liebherr is improvement of the protection of the environment.
  This starts right at the beginning, with the development and construction of our engines. In this way we
  make sure, that no environment-damaging materials are used and, for example, emission values satisfy the
  highest requirements.
• Economical operation helps to conserve our resources and our environment.
• Carefully read the Operating Instructions before starting any work! This is especially valid for the chapter on
• General Safety Instructions and the safety instructions in each of the chapters.
  The non-observance of this operating instruction and all accompanying supplier operating instructions leads
  to the loss of claims under the guarantee.

TABLE OF CONTENTS:

Liebherr D856 Diesel Engine Operating Instruction Manual – PDF DOWNLOAD

Operating Instructions...................................................................................................................  1
Information and Copyright................................................................................................................  2
List of contents.........................................................................................................................  3
1 Foreword...............................................................................................................................  7
	1.1 Information on the Operating Instruction.........................................................................................  7
		1.1.1 Supplementary publications for the engine..................................................................................  7
	1.2 Explanation of symbols...........................................................................................................  8
	1.3 Limitation of liability..........................................................................................................  9
	1.4 Protection of copyright..........................................................................................................  9
	1.5 Other relevant documentation.....................................................................................................  9
	1.6 Spare parts...................................................................................................................... 10
	1.7 Disposal......................................................................................................................... 10
	1.8 Conditions of guarantee.......................................................................................................... 11
	1.9 Customer service................................................................................................................. 11
2 General Safety Instructions............................................................................................................ 13
	2.1 Intended use..................................................................................................................... 13
	2.2 Content of the operating instruction............................................................................................. 14
	2.3 Modifications and changes on the engine.......................................................................................... 14
	2.4 Responsibility of the operator................................................................................................... 14
	2.5 Personnel requirements........................................................................................................... 15
		2.5.1 Qualifications............................................................................................................. 15
		2.5.2 Unauthorised persons....................................................................................................... 15
		2.5.3 Instruction................................................................................................................ 15
	2.6 Personal protection equipment.................................................................................................... 16
	2.7 Special dangers.................................................................................................................. 17
	2.8 Behaviour in the event of danger and accidents................................................................................... 22
	2.9 Signs and notices................................................................................................................ 23
	2.10 Protection of the environment................................................................................................... 24
3 Engine type plate...................................................................................................................... 25
	3.1 Explanation of Type Designation.................................................................................................. 25
	3.2 Air compressor................................................................................................................... 25
	3.3 Diesel engine number............................................................................................................. 25
	3.4 Engine control unit-Type plate................................................................................................... 26
	3.5 Cylinder designation, direction of rotation...................................................................................... 26
4 Construction and function.............................................................................................................. 27
	4.1 Engine, general.................................................................................................................. 27
	4.2 Engine views..................................................................................................................... 28
		4.2.1 View front, left - Variant A............................................................................................... 28
		4.2.2 View, front right, Variant A............................................................................................... 29
		4.2.3 View front, left, Variant B................................................................................................ 30
		4.2.4 View front, right, Variant B............................................................................................... 31
		4.2.5 View front, left, Variant C................................................................................................ 32
		4.2.6 View front, right, Variant C............................................................................................... 33
5 Transport, Packaging and Storage....................................................................................................... 35
	5.1 Prerequisite..................................................................................................................... 35
	5.2 Safety instructions.............................................................................................................. 35
	5.3 Transport inspection............................................................................................................. 38
	5.4 Transport........................................................................................................................ 39
	5.5 Packaging........................................................................................................................ 41
	5.6 Storage.......................................................................................................................... 41
6 Installation and Commissioning......................................................................................................... 43
	6.1 Prerequisite..................................................................................................................... 43
	6.2 Safety instructions.............................................................................................................. 43
	6.3 Installation - Engine............................................................................................................ 44
		6.3.1 Safety devices............................................................................................................. 44
		6.3.2 Data on the engine type plates............................................................................................. 44
	6.4 Commissioning.................................................................................................................... 45
		6.4.1 Fill with diesel fuel...................................................................................................... 45
		6.4.2 Fill with coolant.......................................................................................................... 46
		6.4.3 Fill with engine oil....................................................................................................... 46
7 Control and Operation.................................................................................................................. 47
	7.1 Prerequisite..................................................................................................................... 47
	7.2 Safety instructions.............................................................................................................. 47
	7.3 Preparation before operation..................................................................................................... 48
		7.3.1 Check fuel level and top up................................................................................................ 48
		7.3.2 Check coolant.............................................................................................................. 48
		7.3.3 Top up coolant............................................................................................................. 49
		7.3.4 Check Engine Oil Level..................................................................................................... 50
		7.3.5 Top up with engine oil..................................................................................................... 51
	7.4 Operation........................................................................................................................ 52
		7.4.1 Operation monitoring system................................................................................................ 52
	7.5 Exhaust gas after treatment (SCR)................................................................................................ 53
		7.5.1 Reducing agent............................................................................................................. 53
		Specification.................................................................................................................... 53
		Use / Handling................................................................................................................... 54
		Disposal......................................................................................................................... 54
		Suitability for storage / Temperature resistance................................................................................. 54
		Availability..................................................................................................................... 55
		7.5.2 Inspection and warning lamps............................................................................................... 55
		7.5.3 Warning and fault function strategies...................................................................................... 55
7.5.3 Warning and fault function strategies.............................................................................................. 55
8 Care and Maintenance................................................................................................................... 63
	8.1 Prerequisite..................................................................................................................... 63
	8.2 Safety instructions.............................................................................................................. 63
	8.3 Maintenance Schedule............................................................................................................. 65
	8.4 Maintenance work................................................................................................................. 67
		8.4.1 Engine change.............................................................................................................. 67
		8.4.2 Check the oil pan, engine mounting and engine console for correct seating.................................................. 70
		8.4.3 Check the intake and exhaust system for condition, check sealing........................................................... 71
		8.4.4 Check the valve of the diesel engine brake................................................................................. 71
		8.4.5 Check the flame start system............................................................................................... 71
		To examine the flame start system above 20° C the temperature disconnect can be deactivated, in that the tag connector is ....... 71
		8.4.6 Cleaning fuel pre­cleaner.................................................................................................. 74
		8.4.7 Drain fuel filter - condensation water..................................................................................... 75
		8.4.8 Change fuel filter insert.................................................................................................. 76
		8.4.9 Vent fuel system........................................................................................................... 77
		8.4.10 Check the water separator on the fuel prefilter and drain off water....................................................... 78
		8.4.11 Vent the fuel prefilter................................................................................................... 78
		8.4.12 Replace fuel prefilter element............................................................................................ 79
		8.4.13 Check cooling and heating system for sealing and condition................................................................ 80
		8.4.14 Replace rotary seals and coolant pump bearing............................................................................. 80
		8.4.15 Replace coolant........................................................................................................... 81
		8.4.16 Check the concentration of the corrosion inhibitor in the coolant......................................................... 83
		8.4.17 Use of corrosion inhibitor without frost protection....................................................................... 84
		8.4.18 Greasing the starter ring gear on the flywheel............................................................................ 86
		8.4.19 Check the batteries and cable connections................................................................................. 86
		8.4.20 Check the control unit mounting for condition............................................................................. 86
		8.4.21 Check sensors, actuators, cable mountings and plugs for condition......................................................... 86
		8.4.22 Check the vacuum indicator of the air filter.............................................................................. 86
		8.4.23 Clean the dust discharge valve of the air filter.......................................................................... 86
		8.4.24 Replace the dry air filter main element................................................................................... 87
		8.4.25 Replace dry air filter safety element..................................................................................... 87
		8.4.26 Replace Poly-V belt....................................................................................................... 87
		8.4.27 Visual check (sealing, contamination, damage)............................................................................. 88
		8.4.28 Drain water and residue from fuel tank.................................................................................... 88
		8.4.29 Check valve clearance and adjust.......................................................................................... 89
		8.4.30 Check valve control timing................................................................................................ 97
		8.4.31 Replace the foam and filter element of the SCR carbamide pump.............................................................101
8.4.31 Replace the foam and filter element of the SCR carbamide pump.....................................................................101
9 Faults.................................................................................................................................103
	9.1 Prerequisite.....................................................................................................................103
	9.2 Safety instructions..............................................................................................................103
	9.3 Fault table......................................................................................................................104
10 Decommissioning and recommissioning...................................................................................................109
	10.1 Prerequisite....................................................................................................................109
	10.2 Safety instructions.............................................................................................................109
	10.3 Recommissioning of decommissioned engines.......................................................................................110
		10.3.1 Commissioning of non-preserved engines....................................................................................110
11 Technical data........................................................................................................................111
	11.1 Dimensions and weight...........................................................................................................111
	11.2 Requirements at the installation location, space requirement....................................................................111
	11.3 Engine data.....................................................................................................................112
		11.3.1 D856......................................................................................................................112
12 Lubrication and Fuels, Lubricants and Coolants........................................................................................113
	12.1 Handling Lubrication and Fuels, Lubricants and Coolants.........................................................................113
	12.2 Precautions for protection of the environment...................................................................................113
	12.3 Disposal of used substances.....................................................................................................113
	12.4 Diesel fuel.....................................................................................................................114
		12.4.1 Specification.............................................................................................................114
		12.4.2 Sulphur content in diesel fuel............................................................................................114
		12.4.3 Diesel fuel - Lubrication capability......................................................................................114
		12.4.4 Ignition quality..........................................................................................................114
		12.4.5 Diesel fuel at low temperatures (Winter operation)........................................................................114
	12.5 Lube oil for diesel engines.....................................................................................................115
	12.6 Coolant, Diesel engine..........................................................................................................116
	12.6.6 Approved corrosion inhibitors without frost protection........................................................................119
13 Listings..............................................................................................................................121
	13.1 Abbreviations...................................................................................................................122
	13.2 Specialist words................................................................................................................123
	13.3 Key word listing................................................................................................................124
14 Notes.................................................................................................................................126

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