Liebherr D856 Diesel Engine Operating Instruction Manual - PDF DOWNLOAD

Operating Instructions

Diesel engine D856

“Translation of the original operating instructions”

Diesel Engines D856

Information and Copyright

en

Operating Instructions diesel engine D856

Subject to technical alterations in the interests of further development.

The reprinting, reproduction or translation, even of extracts, is not permitted without the written permission of Liebherr. All rights relating to copyright are expressly reserved by Liebherr.

Document identification Order number: Issued: Document version: Author:

9739991 01.06.2011 00 LMB/Dept.-BE-MD3

Address LIEBHERR MACHINES BULLE S.A. 45, rue de l'Industrie CH-1630 BULLE Switzerland

Manufacturer LIEBHERR MACHINES BULLE S.A

Redaction: 04.2012

2

Diesel Engines D856

List of contents Information and Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

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

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

2

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

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

3

Diesel Engines D856

List of contents 4

5

6

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

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

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

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

Control and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47

7.1

Prerequisite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47

7.2

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47

7.3

Preparation before operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48

6.4

7

7.4 7.5

4

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

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52

7.4.1

Operation monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52

Exhaust gas after treatment (SCR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53

7.5.1

Reducing agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53

7.5.2

Inspection and warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55

7.5.3

Warning and fault function strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55

Diesel Engines D856

List of contents 8

9

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

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

Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

103

9.1

Prerequisite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

103

9.2

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

103

9.3

Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104

5

Diesel Engines D856

List of contents 10

11

12

13

14

6

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

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

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

12.5.1 Lube oil quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115

12.5.2 Lube oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115

12.5.3 Lube oil change intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

116

12.6 Coolant, Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

116

12.6.1 General recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

116

12.6.2 Water (fresh water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

117

12.6.3 Coolant - Mixing ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

117

12.6.4 Approved corrosion inhibiting antifreeze. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

118

12.6.5 Approved, ready-mixed corrosion-inhibiting antifreeze . . . . . . . . . . . . . . . . . . . . . .

118

12.6.6 Approved corrosion inhibitors without frost protection . . . . . . . . . . . . . . . . . . . . . . .

119

Listings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

121

13.1 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

122

13.2 Specialist words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

123

13.3 Key word listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

124

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

126

Diesel Engines D856

Foreword 1

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.

1.1.1

Supplementary publications for the engine

The following instructions are available as a supplement to the operating instruction: For the operator, maintenance and service personnel -

Spare Parts Catalogue (included)

For the service personnel -

Repair Instructions

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Diesel Engines D856

Foreword 1.2 Explanation of symbols Warnings Warnings are identified in these Operating Instructions with symbols. These warnings are prece­ ded by signal words that express the magnitude of the risk.

Always heed these warnings and act prudently to prevent accidents, injuries and property damage.

DANGER! ... indicates an imminently hazardous situation, which leads to death or serious injuries if not avoided.

WARNING! ... indicates a possible hazardous situation, which can lead to death or serious injuries if not avoided.

CAUTION! ... indicates a possible hazardous situation, which can lead to minor or light injuries if not avoided.

IMPORTANT! indicates a possible dangerous situation that can lead to property damage if it is not avoided.

Tips and Recommendations NOTE! highlights useful tips and recommendations as well as information for efficient and smooth operation.

General Information •

This symbol indicates a list at the first level.

-

This symbol indicates a list at the second level.

1.

This symbol indicates a sequence of actions.

(1)

In the text, this symbol indicates a position in a graphic.

8

Diesel Engines D856

Foreword 1.3 Limitation of liability All information and notes in this instruction have been compiled with due consideration of the relevant stan­ dards and specifications, the state of the art and our many years of knowledge and experience.

Liebherr accepts no liability for damages due to: S S S S S S

Failure to follow these instructions Improper use Use of untrained personnel Customer conversions Technical modifications Use of non-approved spare parts and fluids and lubricants

The actual scope of delivery for special versions, additional ordering options or technical modifications may deviate from what is described and illustrated in these instructions.

The responsibilities agreed in the delivery contract, the general conditions of sale and supply of Liebherr and the statutory regulations valid at the time of signing the contract are all applicable.

1.4 Protection of copyright Treat the operating instruction as confidential. It is intended exclusively for use by persons concerned with the engine.

The handing over of this operating instruction to a third party without the written consent of Liebherr is for­ bidden.

NOTE! The information, texts, drawings, illustrations and other depictions are all protected by copy­ right and are subject to industrial property rights. Any improper use is punishable by law.

1.5 Other relevant documentation Supplier components are built into the engine (e.g. injection system). For these bought-in parts risk assess­ ments have been carried out by the respective supplier.

Compliance of the design with the applicable European and national regulations has been declared by the respective component supplier.

9

Diesel Engines D856

Foreword 1.6 Spare parts 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.

Spares and accessories must either be Liebherr original parts or parts expressly approved by Liebherr. For these parts the reliability, safety and suitability for engines has been especially established. Despite on­ going market observation, we are unable to assess this for other products and therefore cannot recom­ mend their use.

WARNING! Risk of injury from incorrect spare parts!

Incorrect or faulty spare parts can lead to damage, malfunctions or total failures and in­ terfere with safety.

For this reason: S Only use Liebherr original spare parts NOTE! On all communications and enquiries, please state engine type and engine number, see page 25.

Order spares via approved dealer or direct from Liebherr. For address, see page 2.

1.7 Disposal Dispose in accordance with national regulations.

If no return or disposal agreement has been made, recycle the disassembled components as follows: S

Sort metals before scrapping

S

Recycle plastic parts

S

Dispose of all other parts according to their material composition

10

Diesel Engines D856

Foreword 1.8 Conditions of guarantee The responsibilities agreed in the delivery contract, the general conditions of sale and supply of Liebherr and the statutory regulations valid at the time of signing the contract are all applicable.

The non-observance of this operating instruction and all accompanying supplier operating instructions leads to the loss of claims under the guarantee.

The use of non-approved parts leads to the loss of warranty claims.

Even after the expiry of the guarantee period we recommend the use of original parts, in order to ensure the continuing performance capability of the engine.

1.9 Customer service Our Liebherr customer service is at your disposal for technical information.

NOTE! On all communications and enquiries, please state engine type and engine number, see page 25.

Information on appropriate contacts can be obtained at anytime by Telephone, Fax, E-mail or via the Inter­ net. For address, see page 2.

11

Diesel Engines D856

Foreword

12

Diesel engines D856

General Safety Instructions 2

General Safety Instructions

This chapter provides information on residual risks and hazards during proper use of the engine. The gene­ rally valid safety instructions to be observed are listed here. They provide optimum protection for personnel and for the safe and smooth operation of the engine.

In the following, specific, action and situation-related safety information is placed before the corresponding step, or in the chapter described.

Failure to observe the Operating Instructions and Safety Instructions in this document can result in signifi­ cant hazards.

2.1 Intended use The engine is built exclusively for installation in self-propelled working machines.

Any other use is considered as "not intended".

Liebherr is not liable for any damage resulting from such use. The risk is carried exclusively by the opera­ tor.

Intended use also includes compliance with the prescribed operating, maintenance and repair work.

The engine may only be used, maintained and repaired by persons who are familiar with the engine and have been informed of the hazards.

Unauthorised modifications to the engine exclude any liability for any resulting damage to property and in­ jury to persons.

Likewise, the manipulation of the injection and control system could affect the performance and emission characteristics of the engine. Compliance with the statutory environmental requirements can therefore no longer be guaranteed.

DANGER! Danger from not using the product as intended!

Any use that exceeds the intended use and/or any different use of the engine can lead to dangerous situations which will invalidate the operating permit.

For this reason: S Only use the engine as intended.

NOTE! Observe the following information when operating the engine: S The safety information in these Operating Instructions and in the supplier's operating in­ structions.

S The chapter “Technical Data" in these operating instructions and in the supplier's operating instructions.

S Country-specific regulations.

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Diesel engines D856

General Safety Instructions 2.2 Content of the operating instruction All persons, who are required to work on or with the engine, must have read and understand the operating instruction before commencing work on the engine. This also applies when the person concerned has al­ ready worked on such an engine, or on a similar engine, or has been trained by Liebherr.

Reading and understanding the Operating Instructions is thus mandatory.

2.3 Modifications and changes on the engine To avoid danger and in order to ensure optimum performance, no modifications, additions or changes may be made on the engine, unless these have been expressly approved by Liebherr.

If modifications are undertaken without the written permission of Liebherr, Liebherr will no longer be liable for any guarantee or warranty cover for damage and faults, which result from the unauthorised modifica­ tion. Furthermore, Liebherr is then no longer liable for damages that have resulted as a consequence of the unapproved modification.

2.4 Responsibility of the operator The operator of the engine is subject to the statutory requirements for workplace safety.

In addition to the Safety Instructions in these Operating Instructions, the safety regulations, accident pre­ vention regulations and environmental protection regulations valid for the application area of this engine must also be observed.

In particular: S The operator must be knowledgeable about the valid occupational health and safety regulations and be able to assess, in a risk analysis, the dangers that are present in the specific working conditions at the operating site of the engine. He must then implement these safety regulations in the form of operating instructions for the operation of the engine.

S During the entire period of operation of the engine the operator must check whether the operating in­ structions he created meet the most current standards for regulations and revise them if necessary.

S The operator must clearly define and regulate the responsibilities for installation, operation, maintenance and cleaning of the product.

S The operator must ensure that all staff who deal with the engine have read and understood the Opera­ ting Instructions.

In addition, the operator must periodically train the staff and inform them about hazards.

S The operator must provide the personnel with the necessary protective equipment.

S These operating instructions must be kept in the immediate vicinity of the engine and be readily accessi­ ble at any time to those persons working on and with the engine.

The operator is responsible for ensuring that the engine is always operated in perfect working condition and working order.

In particular: S Carry out the maintenance work, as described in this operating instruction and in the maintenance in­ struction, completely and at the prescribed intervals of time, or arrange for this work to be carried out by a Liebherr workshop/Liebherr contractual partner.

S The operator must have all safety equipment checked regularly for function and integrity.

S The instructions in the Operating Instructions are to be followed completely and fully!

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Diesel engines D856

General Safety Instructions 2.5 Personnel requirements 2.5.1

Qualifications WARNING! Risk of injury caused by insufficient qualifications!

Improper handling can result in significant personal injury and property damage.

For this reason: S Specific activities must only be performed by those persons who are named in the re­ spective chapters in these Operating Instructions.

The following qualifications will be designated in the Operating Instructions for various task areas.

S

Instructed Persons Have been instructed in a briefing about the possible dangers of improper handling in their tasks.

S

Qualified Personnel Due to their technical training, knowledge and experience and knowledge of the relevant regulations they can properly perform the tasks assigned to them.

S

Electrical specialist is, on the basis of his specialist training, knowledge and experience, as well as his knowledge of the ap­ plicable standards and specifications, qualified to carry out work on electrical systems and is able to in­ dependently recognise and avoid potential dangers.

The electrical specialist is trained for the particular place of use, in which he is active, and knows the relevant standards and regulations.

Only those persons who are known to reliably carry out their work should be appointed as personnel. Per­ sons, whose capability to react, e.g. due to the intake of drugs, alcohol or medication, are to be regarded as unsuitable for this function.

S

When selecting personnel, observe the regulations regarding age and profession valid at the operating site.

2.5.2

Unauthorised persons WARNING! Danger for unauthorised persons!

Unauthorised persons, who do not satisfy the requirements described here, do not appre­ ciate the dangers in the work area.

For this reason: S Keep unauthorised persons away from the work area.

S In case of doubt, address the person and remove him/her from the working area if ne­ cessary.

S Stop work, until unauthorised persons have vacated the work area.

2.5.3

Instruction

Personnel must be regularly instructed. To provide traceability, the execution of such instruction must be recorded.

15

Diesel engines D856

General Safety Instructions 2.6 Personal protection equipment During work the wearing of personal protection equipment is necessary to minimise the risk to health.

S

The required personal protective equipment for the relevant job must always be worn while working.

S

All signs pertaining to personal protective equipment in the working area must be followed.

Protective Clothing Close-fitting clothing with low initial tear strength, with narrow sleeves and with no pro­ truding parts. It is used primarily to protect against injury, weather and dirt.

No rings, bracelets, necklaces and other jewellery are to be worn while working.

Protective Helmet To protect the head from falling or flying objects.

Safety Shoes To protect the feet from heavy falling objects and from slipping on slick surfaces.

Safety Gloves To protect the hands from friction, scraping, punctures or deep injuries and to protect from hot or caustic parts or fluids

To be worn when performing specific types of work When performing certain types of work, special protective equipment is required. These will be specifically mentioned in the relevant chapters.

Safety Glasses To protect the eyes from flying objects and spraying fluids.

Hearing Protection To protect the ears from damage by loud noises.

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Diesel engines D856

General Safety Instructions 2.7 Special dangers The following section describes residual risks which have been identified.

S

Observe the safety instructions listed here and the warnings in the other chapters of these instructions in order to reduce health hazards and avoid dangerous situations.

Electrical Current DANGER! Risk of death caused by electrical current!

There is a risk of death when coming into contact with parts conducting electrical currents.

Damaged insulation or components can be life threatening.

For this reason: S If the insulation is damaged, immediately switch off the power supply and get the insu­ lation repaired.

S Any work performed on the electrical system may only be made by a qualified electrician.

S When working on the electrical system the power supply must be switched off and then properly checked to ensure no electrical current is present.

S Before starting any maintenance, cleaning or repair work the power supply must be swit­ ched off and secured from being accidentally switched back on.

S Do not bridge or bypass any fuses. When replacing fuses, ensure to use the correct am­ perage.

S Keep moisture clear of parts conducting electrical current. This could cause a short-cir­ cuit.

Moving Parts WARNING! Risk of injury caused by moving parts!

Rotating or linear moving parts can cause serious injuries.

For this reason: S During operation do not reach into or tamper with moving parts.

S Do not open the covers during operation.

S Observe the run-on time: before opening any covers ensure that no parts are still moving.

S Wear close-fitting clothing in the hazard area.

17

Diesel engines D856

General Safety Instructions Heavy Suspended Loads WARNING! Danger of death due to falling loads!

During lifting operations, loads can swing out and fall down. This can cause serious injury and even death.

For this reason: S Use the crane eyes only for the transport of the engine, without additional components.

S A diagonal pull is not permitted, therefore use lifting gear.

Highly Flammable Substances - Diesel Fuel, Oils and Grease WARNING! Risk of fire caused by highly flammable substances!

Highly flammable materials, liquids or gases, can catch fire and lead to severe and even fatal injuries.

For this reason: S Do not smoke in the hazard area or in the vicinity.

No open fires or sources of ignition.

S Keep fire extinguishers at hand.

S Immediately report any suspicious substances, fluids or gases to the person in charge.

S In the case of fire, immediately stop working. Leave hazard area until the danger is over.

Coolants - Antifreeze, Anticorrosion Agents WARNING! Risk of injury caused by coolants that are hazardous to health Coolants contain substances that are hazardous to your health. Contact with these sub­ stances can lead to serious poisoning, allergies, skin irritations and damage to eyes.

For this reason: S Observe the safety sheets from the manufacturer.

S Always wear protective clothing, chemical-resistant protective gloves and safety glasses.

S Avoid spilling or spraying these substances.

Hot Fluids and Lubricants WARNING! Risk of burns caused by hot fluids and lubricants!

Fluids and lubricants can reach high temperature while in operation and cause burns when coming into contact with them.

For this reason: S Before handling any fluids and lubricants, check whether they are hot. If necessary, let them cool down first.

18

Diesel engines D856

General Safety Instructions Hot Surfaces CAUTION! Risk of burns caused by hot surfaces!

Contact with hot components can cause burns.

For this reason: S When performing any work in the vicinity of hot components always wear protective clo­ thing and protective gloves.

S Before starting any work ensure that all components have cooled down to ambient tempe­ rature.

Noise WARNING! Risk of hearing damage caused by noise!

The level of noise occurring in the working area can cause serious damage to hearing.

For this reason: S Always wear hearing protection when working.

S Do not unnecessarily remain in the hazard area. Leave hazard area when work is finis­ hed.

Sharp Edges and Corners CAUTION! Risk of injury cause by sharp edges and corners!

Sharp edges and corners can cause cuts and scrapes to the skin.

For this reason: S Always work carefully and with caution in the vicinity of sharp edges and corners.

S In cases of doubt, wear protective gloves.

Dirt and Objects CAUTION! Risk of tripping caused by dirt and objects!

Dirt and objects can cause a person to slip or trip which can cause considerable injuries.

For this reason: S Always keep the work area clean.

S Remove any objects that are no longer necessary.

S Mark areas where there is a danger of tripping with yellow and black striped tape.

19

Diesel engines D856

General Safety Instructions Working on the Common Rail System WARNING! Risk of injury caused by fluids exiting under high pressure!

Fuel lines under high pressure (1800 bar) can cause considerable injuries.

For this reason: S Work on the common rail system must only be performed by trained and qualified per­ sonnel.

S Before starting any work on the common rail system the engine must be switched off.

Wait until the pressure in the system has been released.

WARNING! Risk of death caused by spraying fluids!

Fluid can exit under high pressure from faulty lines or machine components.

The fluid jet can sever body parts and lead to severe injuries and death.

For this reason: S Never touch the stream of an exiting fluid.

S Properly clean up and dispose of fluids that have exited the system.

S Get the faulty parts repaired.

WARNING! Risk of death caused by hydraulic power!

Hydraulic power can cause serious to deadly injuries.

Hydraulic powered parts can move unexpectedly.

If components are damaged, hydraulic fluid can exit under high pressure.

For this reason: S Work on the hydraulic system must only be performed by trained and qualified personnel.

S Before commencing work on the hydraulic system, this must first be switched off and de­ pressurised. Pressure accumulators must be completely depressurised. Check for com­ plete absence of pressure.

S Do not change the pressure setting above the maximum value.

WARNING! Risk of death caused by strong magnetic fields!

Strong magnetic fields can cause serious injuries and death as well as considerable property damage.

For this reason: S Persons with cardiac pacemaker must not remain in the vicinity of the engine.

The operation of the cardiac pacemaker could be negatively affected.

S Persons with metal implants must not remain in the vicinity of the engine. Metal implants could heat up or be attracted to the magnetic source.

S Keep ferromagnetic materials and electromagnets away from magnetic sources. These materials can be magnetically attracted and can fly through the room and injure people or cause death. Keep a minimum distance of 3 m.

S Take off all metal objects (jewellery, watches, pens, etc.) before starting any maintenance work.

S No electronic equipment must be positioned close to a magnetic source. This equipment could become damaged.

S Do not take any memory devices, credit cards, etc. near the magnetic source. Data could be erased.

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Diesel engines D856

General Safety Instructions Exhaust gas after treatment system (SCR) IMPORTANT! Water, steam or other cleaning agents may ingress into the SCR module!

The coating of the substrates detaches.

NOx Sensor defect.

For this reason: S Before cleaning, cover all openings.

S Make sure that no fluids or dirt pass into the tailpipe opening of the SCR module.

S Allow the SCR system to cool down before cleaning (surface temperature < 50 °C).

21

Diesel engines D856

General Safety Instructions 2.8 Behaviour in the event of danger and accidents Preventative Measures S S S S S S

Always be prepared for an accident!

Keep first aid equipment (first aid kit, blankets, etc.) and fire extinguishers at hand.

Check first aid equipment and fire extinguishers regularly for completeness and proper operation.

Make sure that all persons are familiar with accident alarm, first aid and rescue equipment and procedu­ res.

Instruct the personnel on safety on a regular basis.

Always keep access lanes for rescue vehicles free of any obstructions.

In the case of an accident: Act accordingly S S S S S S

Remain calm.

Start first aid measures.

Alert rescue services and/or fire department.

Move people out of the danger zone.

Clear access lanes for rescue vehicles.

Inform the person in charge.

CAUTION! Accidents despite preventative measures If an accident occurs, e.g. from one of the listed points below, despite all of the preventative measures, contact a physician immediately.

S Contact with caustic acids.

S Penetration of fuel into the skin.

S Scalding by hot oil or coolant.

S Antifreeze sprayed into the eyes, etc..

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Diesel engines D856

General Safety Instructions 2.9 Signs and notices The following symbols should be installed in the immediate vicinity of the hazard area.

WARNING! Risk of injury caused by illegible symbols!

Stickers and symbols can become dirty or made otherwise illegible in the course of time!

For this reason: S Always keep the safety, warning and operational signs in good legible condition.

S Clean or replace illegible safety, warning and operational signs

Electrical voltage Rooms and areas marked with this symbol may only be accessed by qualified electri­ cians.

Unauthorised persons must not such areas.

Hot Surfaces Hot surfaces, such as hot engines and hot liquids, are not always perceptible. Do not touch these surfaces without protective gloves.

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Diesel engines D856

General Safety Instructions 2.10 Protection of the environment CAUTION! Environmental hazard caused by incorrect handling!

Incorrect handling of environmentally hazardous substances, especially when incorrectly disposed of, can cause considerable damage to the environment.

For this reason: S Always heed the information below.

S If environmentally-hazardous substances find their way into the environment, take suita­ ble immediate precautions. In cases of doubt inform the relevant local authority of the damage.

The following environmentally hazardous substances are used: Lubricants Lubricants such as grease and oils contain poisons and environmentally hazardous substances. They must not be allowed to be released into the environment. Disposal must be performed by a qualified disposal company.

Diesel Fuel Diesel fuel contains poisons and environmentally hazardous substances. They must not be allowed to be released into the environment. Disposal must be performed by a qualified disposal company.

Coolants Coolants can contain poisons and environmentally hazardous substances. They must not be allowed to be released into the environment. Disposal must be performed by a qualified disposal company.

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Diesel engines D856

Engine Model Plate 3

Engine type plate

The engine type plate is affixed to the flywheel side of the crankcase.

3.1 Explanation of Type Designation Model designation

Explanation

Example

D

Fuel type

Diesel

85

Bore 126 mm

6

Number of cylinders

6 cylinders

Item

Value

Unit

Output delivery at rated 1900 min-1 and 6 bar

465

l/min

Transmission ratio

1 : 1,388

Water cooled

yes

3.2 Air compressor

3.3 Diesel engine number The diesel engine number is stated on the Engine type plate.

There is also an assembly number on the crank­ case, on the flywheel, as seen from the right.

(1) (2) (3)

Date No. of cylinders Sequential number.

S

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Diesel engines D856

Engine type plate 3.4 Engine control unit-Type plate (1) Engine Ident No. (2) Engine Serial No. (3) Control unit Ident No. (4) Modification Index (5) Software Version (6) Control unit serial No. (7) Date of delivery (8) 2D Codebar (9) Engine type (10) Control unit designation

NOTE! The information on the engine control unit type plate corresponds to the condition on delivery (Ex-Works Liebherr Machines, Bulle). Depending on the software updates in the field, it may be that this information is no longer up-to-date. The current information can be called up on the equipment display or read out using the Liebherr Diagnostic and Service Tool, Sculi.

3.5 Cylinder designation, direction of rotation Cylinder 1 is towards the flywheel side.

The cylinder numbers are cast to the right on the top of the crankcase, as seen from the flywheel, as is the ignition sequence.

26

Diesel Engines D856

Design and Function 4

Construction and function

4.1 Engine, general The 6-cylinder engines described here are liquid-cooled, supercharged 4-stroke diesel engines with ex­ haust gas turbocharging and intercooling.

The engines operate with the Common Rail high pressure injection system in association with EDC7 (Elec­ tronic-Diesel-Control).

Engine Monitoring Monitoring of the engine is made through various sensors. The sensors are designed, for example, as rpm and temperature sensors, which report the various operating conditions of the engine to the engine control unit. The engine control unit operates according to the EVA principle: E = Eingang (Input) V = Verarbeitung (Processing) A = Ausgang (Output) The engine control unit processes the received sensor information and controls the output signals which are sent to the actuators. The actuators convert the signals into mechanical factors.

One of the actuators, for example, is the metering unit on the high-pressure pump.

Engine Lubrication The engine lubrication takes place through a forced feed lubrication system for all bearings. The engine oil filter and the oil cooler are combined as an oil module. The oil level measurement takes place in the oil pan by means of an oil dipstick and via an oil level sensor built into the crankcase.

Cooling System On the cooling circuit there is a thermostat-regulated forced flow cooling system with a maintenance-free coolant pump driven by the V-ribbed belt. The distributor housing facilitates the location of the coolant pump. Also the connection for the heating flow pipe is attached on the distributor housing. The thermostats, alternative short-circuit inserts for the outlying thermostats, are replaceable inserts.

Intake and Exhaust System The 3-part exhaust manifold is made from high temperature-resistant spheroidal graphite iron and secured on the cylinder head with high temperature bolts. The maintenance-free turbocharger is installed on the centre exhaust manifold. The lubrication of the exhaust turbocharger takes place via the engine oil circuit.

Fuel System, General The fuel system is divided into a low-pressure and a high-pressure system.

The fuel lines, the hand delivery pump and also the KSC (Fuel-Service-Center) belong to the low-pressure system. The KSC comprises a prefilter and special fine filter with water separation, in order to guarantee the fuel purity required by the common rail system. In addition the low-pressure system incorporates a hea­ ting element and a flame start system. The interface to the high-pressure system is the fuel delivery pump.

The high pressure system consists of the quantity-regulated High-pressure pump with a flange-mounted fuel delivery pump and the pressure pipe with rail pressure sensor and pressure-limiting valve. In addition, solenoid valves, injectors with pressure pipe connections and also the corresponding high pressure pi­ pelines to satisfy the requirements are built in.

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Diesel Engines D856

Design and Function 4.2 Engine views 4.2.1

View front, left - Variant A

(1) Cylinder head cover (2) Oil filler neck (3) Cylinder head (4) Coolant lines to the retarder (5) Injector cable loom (6) Air compressor (7) Rail/Pressure pipe (8) Fuel-Service-Center (KSC) (9) Oil pan (10) Oil drain valve (11) Fuel-Hand pump (12) Oil dipstick (13) High-pressure pump (14) Vibration damper (15) Fan hub (16) Alternator (17) Solenoid valve (18) Flame glowplug

28

Diesel Engines D856

Design and Function 4.2.2

View, front right, Variant A

(1) Oil separator (2) Oil filter (3) Charge air inlet (4) Coolant outlet (5) Coolant pump (6) Coolant inlet (7) Turbocharger (8) Starter (9) Charge air outlet (10) Suction hose (11) Coolant line from the retarder (12) Throttle valve (13) Power take-off (14) Exhaust outlet

29

Diesel Engines D856

Design and Function 4.2.3

View front, left, Variant B

(1) Cylinder head cover (2) Oil filler neck (3) Cylinder head (4) Coolant line to the retarder (5) Injector cable loom (6) Air compressor (7) Rail/Pressure pipe (8) Fuel-Service-Center (KSC) (9) Oil pan (10) Oil drain valve (11) Fuel-Hand pump (12) Oil dipstick (13) High-pressure pump (14) Vibration damper (15) Fan hub (16) Alternator (17) Solenoid valve (18) Flame glowplug

30

Diesel Engines D856

Design and Function 4.2.4

View front, right, Variant B

(1) Oil separator (2) Oil filter (3) Charge air inlet (4) Coolant outlet (5) Coolant pump (6) Coolant inlet (7) Turbocharger (8) Starter (9) Charge air outlet (10) Suction hose (11) Coolant line from the retarder (12) Throttle valve (13) Power take-off (14) Exhaust outlet

31

Diesel Engines D856

Design and Function 4.2.5

View front, left, Variant C

(1) Cylinder head cover (2) Oil filler neck (3) Cylinder head (4) Flywheel housing/Timing case (5) Injector cable loom (6) Rail/Pressure pipe (7) Fuel-Service-Center (KSC) (8) Oil pan (9) Oil drain valve (10) Fuel-Hand pump (11) Oil dipstick (12) High-pressure pump (13) Vibration damper (14) Alternator (15) Solenoid valve (16) Charge air inlet

32

Diesel Engines D856

Design and Function 4.2.6

View front, right, Variant C

(1) Oil separator (2) Oil filter (3) Flame glow plug (4) Coolant outlet (5) Coolant pump (6) Coolant inlet (7) Turbocharger (8) Starter (9) Charge air outlet (10) Suction hose (11) Throttle valve (12) Exhaust outlet

33

Diesel Engines D856

Design and Function

34

Diesel Engines D856

Transport, Packaging and Storage 5

Transport, Packaging and Storage

When installing and commissioning a new or overhauled engine, follow the “Installation Instruction” uncon­ ditionally.

NOTE! The installation and commissioning is undertaken exclusively by employees of the manufac­ turer of the complete plant, or by persons appointed by the manufacturer.

Nevertheless, as part of the installation and the use of the engine, situations will occur where the operator or his maintenance personnel will have to be familiar with the handling of packages. In these situations it is absolutely necessary to observe the following informa­ tion.

5.1 Prerequisite Before commencing work, read and adhere to the General Safety Instructions and the Safety Instructions in this chapter.

Follow the instructions unconditionally and proceed with care and attention, in order to avoid accidents and injury to persons and damage to property.

Personal Protective Equipment The following protective equipment must be worn: S S S S

Protective Clothing Protective Helmet Safety Shoes Safety Gloves

5.2 Safety instructions Heavy Suspended Loads WARNING! Risk of death caused by heavy suspended loads!

During lifting operations, loads can swing out and fall down. This can cause serious injury and even death.

For this reason: S Do not stand under or remain in the swivel range of the suspended load.

S Only move the load under supervision.

S Only use approved lifting equipment and accessories with sufficient load capacity.

S Never use torn or scuffed lifting equipment such as ropes or straps.

S Do not let lifting equipment such as rope or straps come into contact with sharp edges and corners and do not twist or knot them.

S Before leaving the work area, lower load to ground.

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Diesel Engines D856

Transport, Packaging and Storage

WARNING! Danger of death due to falling loads!

During lifting operations, loads can swing out and fall down. This can cause serious injury and even death.

For this reason: S Use the „crane eyes“ only for the transport of the engine, without additional components.

S A diagonal pull is not permitted, therefore use lifting gear.

Offset centre of gravity WARNING! Risk of injury caused by falling or tipping packages!

Packages can have a centre of gravity that is off-centre. If the lifting equipment is not hoo­ ked up properly, these packages could tip over and fall causing serious injuries.

For this reason: S Observe the information and markings on the package concerning centre of gravity.

S When transporting with a crane, the hook must be placed so that it is directly above the package's centre of gravity.

S Carefully raise the package and observe its movement. If necessary, change the position of the lifting equipment.

Swinging load WARNING! Risk of injury due to swinging loads!

During transport with the crane the load can swing out and cause severe injuries and damage to property.

For this reason: S Ensure that during the transport of packages, no persons, objects or obstacles are in the swivel range of the packages being transported.

Unauthorised Transport IMPORTANT! Risk of property damage if packages are transported by untrained personnel!

Improper transport by untrained personnel can cause packages to fall or tip over. This could cause considerable property damage.

For this reason: S The unloading of transported packages/loads on delivery and also their internal transportation must only be carried out by trained personnel under instructions from em­ ployees of the manufacturer.

S Refrain from any unauthorised transportation or removal of the transportation aids.

S No unauthorised removal of packaging permitted.

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Diesel Engines D856

Transport, Packaging and Storage Improper Transport IMPORTANT! Risk of property damage caused by improper transport!

Improper transport can cause packages to fall or tip over. This could cause considerable property damage.

For this reason: S When unloading packages on delivery and in internal transportation proceed very care­ fully and follow the information on the packaging.

S Only use the prescribed lifting points.

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Diesel Engines D856

Transport, Packaging and Storage 5.3 Transport inspection Check the delivery for missing items and for damage from transport.

If external signs of transport damage are apparent: S

Do not accept delivery or only accept under written protest.

S

List scope of damage on the transport documents or on the transportation company's packaging slip.

S

Initiate a claims process.

NOTE! Make sure to claim each damage case as soon as it is discovered. Damage claims can only be claimed within the applicable time limits.

38

Diesel Engines D856

Transport, Packaging and Storage 5.4 Transport Lifting Points

3 crane hook eyes (1), (2) and (3) are provided on the engine for the purpose of lifting it.

WARNING! Danger of death due to falling loads!

During lifting operations, loads can swing out and fall down. This can cause serious injury and even death.

For this reason: S Use the „crane eyes“ only for the transport of the engine, without additional components.

S A diagonal pull is not permitted, therefore use lifting gear.

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Diesel Engines D856

Transport, Packaging and Storage Transport with Crane The engine can be transported with a crane under the following conditions.

S S

The crane and the lifting equipment must be designed for the weight of the engine.

The operator must be qualified for operating the crane.

1. Use ropes, belts or multi-point suspensions in accordance with the illustration.

2. Ensure that the transported packages are hanging straight, and allow for an offset centre of gravity, where applicable.

3. Start the transport.

Transport with the fork lift The engine can be transported with a fork lift under the following conditions.

S S S

The forklift must be designed for the weight of the engine.

The engine must be securely mounted to the pallet.

The forklift driver must be qualified to drive the forklift and authorised to do so.

1. Drive the forklift with the forks inserted between or below the spars of the pallet.

2. The fork must be inserted into the pallet until it protrudes from the other side.

3. Ensure that the pallet cannot tip over due to an off-centre centre of gravity.

4, Lift the pallet and transport it to the desired location.

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Diesel Engines D856

Transport, Packaging and Storage 5.5 Packaging Packaging The individual packages are packed in accordance with the expected conditions of transport.

The purpose of the packaging is to protect the components from transport damage, corrosion and other damage. For this reason do not unpack components until shortly before they are to be assembled.

Handling Packing Material Dispose of packing material according to the valid local and statutory regulations.

IMPORTANT! Risk of hazard to the environment caused by incorrect disposal!

Packaging materials are valuable raw materials and can in many cases continue to be used or can be processed and recycled. Incorrect disposal of packaging materials may cause an environmental hazard.

For this reason: S Dispose of packing materials in an environmentally friendly manner.

S Observe the valid local regulations. If necessary, contact a professional disposal com­ pany.

5.6 Storage Storage of packages Store packages under the following conditions: S S S S S S S S

Do not store in the open.

Store in a dry and dust-free environment.

Do not expose to damaging chemicals.

Protect from sun light.

Avoid any physical shocks.

Storage temperature: 15 to 35 °C. Relative humidity: max. 60 %.

If stored for more than 3 months, regularly check the condition of the packaging. If necessary, renew or replace the preservation.

NOTE! Some of the packages may have information printed on them regarding their proper sto­ rage. Please observe this information.

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Diesel Engines D856

Transport, Packaging and Storage

42

Diesel Engines D856

Installation and Commissioning 6

Installation and Commissioning

6.1 Prerequisite Before commencing work, read and adhere to the General Safety Instructions and the Safety Instructions in this chapter.

Follow the instructions unconditionally and proceed with care and attention, in order to avoid accidents and injury to persons and damage to property.

Personal Protective Equipment The following protective equipment must be worn: S S S

Protective Clothing Safety Shoes Safety Gloves

6.2 Safety instructions Personnel S

The installation and commissioning must only be carried out by Liebherr employees or by specialist per­ sonnel trained by Liebherr.

WARNING! Danger caused by faulty installation and commissioning!

Installation and commissioning require trained qualified personnel with sufficient experi­ ence. Faulty installation can cause life threatening situations and considerable property damage.

For this reason: S Installation and commissioning is carried out exclusively by Liebherr employees.

S Specialist personnel trained by Liebherr may only carry out the installation and com­ missioning with the permission of Liebherr.

Ground Rules WARNING! Risk of injury caused by improper installation and commissioning!

Improper installation and commissioning can cause serious personal injury or considerable property damage.

For this reason: S Ensure adequate work space before starting any work.

S Be careful when working with exposed parts with sharp edges.

S Make sure work space is kept clean and orderly!

S Install components in a correct manner.

S Observe the prescribed tightening torque.

S Secure components so that they do not fall or tip over.

S

Before commissioning the engine read the operating instruction carefully and become familiar with the “critical” points.

S

When installing and commissioning a new or overhauled engine, follow the “Installation Instruction” un­ conditionally.

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Diesel Engines D856

Installation and Commissioning S

For safety reasons we recommend placing an off limits sign on the door to the engine room and to in­ struct the operating personnel that they are responsible for the safety of people who enter the engine room.

6.3 Installation - Engine The installation of the engine, i.e. the connection of the power supply and connection of the cooling system, are to be carried out in accordance with information provided by the manufacturer.

6.3.1

Safety devices WARNING! Danger of death due to incorrect operation!

In the event of overload or faults the engine may overheat and then suddenly 'freeze up'.

For this reason: S The sensors for the monitoring of the engine parameters must be connected to a monito­ ring device of the module manufacturer and evaluated.

S If the sensors indicate values outside the permissible limits, or if there is a loss of power, the engine must be immediately brought to a standstill by the monitoring device.

6.3.2

Data on the engine type plates

On all communications and enquiries, always state engine type and engine number.

Therefore, before commissioning the engine read the data required from the engine type plates and enter this in the chapter on engine type plates, see page 25.

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Diesel Engines D856

Installation and Commissioning 6.4 Commissioning Do not run new or reconditioned engines during the first operating hours above 3/4 load. However, make sure that the engine speed is varied.

After this time period the engine can be slowly brought up to full power.

IMPORTANT! S Use only approved Fuels, Lubricants and Coolants (see chapter 12)

6.4.1

Fill with diesel fuel DANGER! Risk of fire caused by diesel fuel!

Diesel fuel is highly flammable.

For this reason: S No smoking and no open fires when handling fuels.

S Only refuel with engine off.

S Ensure cleanliness.

S Do not let fuel drip or leak out.

1. Fill with diesel fuel in accordance with the information of the manufacturer of the complete plant.

2. Open fuel shutoff valve.

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Diesel Engines D856

Installation and Commissioning 6.4.2

Fill with coolant NOTE! When filling, do not spill the coolant. No coolant must ingress into the soil or into sources of water. Otherwise the environment will be damaged.

The engine cooling system must be filled with an antifreeze and a corrosion inhibitor, see chapter 12.

Coolant must be filled in accordance with the filing instruction of the vehicle manufacturer.

6.4.3

Fill with engine oil IMPORTANT! Component damage caused by over filling!

Engine damage can occur if engine oil is filled to above the max. mark on the oil dipstick.

For this reason: S Do not fill above the max. notch on the oil dipstick.

MAX MIN

1. Remove cap (1).

2. Slowly fill engine oil into the filler neck.

For oil filling quantity, see “Technical Data”, page 112.

3. Reinstall cap (1).

46

Diesel Engines D856

Operation 7

Control and Operation

7.1 Prerequisite Before commencing work, read and adhere to the General Safety Instructions and the Safety Instructions in this chapter.

Follow the instructions unconditionally and proceed with care and attention, in order to avoid accidents and injury to persons and damage to property.

Personal Protective Equipment The following protective equipment must be worn: S S S

Protective Clothing Safety Shoes Safety Gloves

7.2 Safety instructions Personnel S

Operation of the engine may only be performed by instructed personnel or by trained qualified per­ sonnel.

Ground Rules WARNING! Danger caused by faulty operation!

Improper operation can cause serious personal injury or considerable property damage.

For this reason: S Perform all operating steps in accordance with the instructions in these Operating Instruc­ tions.

S Before starting any work ensure that all covers and protective equipment have been in­ stalled and are operating properly.

S Never shut off any safety equipment while in operation.

S Make sure work space is kept clean and orderly! Any unused parts or components lying around are potential sources of accidents.

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Diesel Engines D856

Operation 7.3 Preparation before operation Before operation, check fuel supply, level of coolant and oil in the engine.

If necessary, refill diesel fuel, coolant and oil.

IMPORTANT! S Use only approved Fuels, Lubricants and Coolants (see chapter 12).

7.3.1

Check fuel level and top up DANGER! Risk of fire caused by diesel fuel!

Diesel fuel is highly flammable.

For this reason: S No smoking and no open fires when handling fuels.

S Only refuel with engine off.

S Ensure cleanliness.

S Do not let fuel drip or leak out.

1. Check fuel supply and refuel in accordance with the instructions of the manufacturer of the entire sys­ tem.

2. Open fuel shutoff valve.

7.3.2

Check coolant WARNING! Risk of scalding!

The cooling system is under pressure and the coolant is hot.

For this reason: S First allow the engine to cool.

When checking the coolant level follow the instructions of the vehicle manufacturer.

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Diesel Engines D856

Operation 7.3.3

Top up coolant NOTE! When filling, do not spill the coolant. No coolant must ingress into the soil or into sources of water. Otherwise the environment will be damaged.

The engine cooling system must be filled with an antifreeze and a corrosion inhibitor, see chapter 12 Coolant must be filled in accordance with the filing instruction of the vehicle manufacturer.

Take care, that the mixing ratio “Water-antifreeze" is restored.

If the mixture of antifreeze and corrosion inhibitor is incorrect, this can lead to lime and rust deposits in the engine coolant circuit, which impairs the cooling effectiveness and function of the coolant pump.

In such cases it is necessary to clean the coolant circuit at appropriate intervals.

49

Diesel Engines D856

Operation 7.3.4

Check Engine Oil Level NOTE! Check the oil level with the engine horizontal, approx. 20 minutes after shutting down the machine.

1. Pull out oil dipstick (1).

2. Wipe off oil dipstick with a lint-free cloth.

3. Reinsert the oil dipstick up to the stop.

4. Pull out oil dipstick again and check oil level.

The oil level should be between both of the marks on the dipstick and should never drop below the lower mark.

5. Reinsert the oil dipstick (1) all the way.

If the oil level is too low, refill with new oil.

MAX MIN

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Diesel Engines D856

Operation 7.3.5

Top up with engine oil IMPORTANT! Component damage caused by over filling!

Engine damage can occur if engine oil is filled to above the max. mark on the oil dipstick.

For this reason: S Do not fill above the max. notch on the oil dipstick.

MAX MIN

1. Remove cap (1).

2. Slowly fill engine oil into the filler neck.

The oil level should be between both marks on the dipstick.

3. Reinstall cap (1).

4. Check engine oil level.

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Diesel Engines D856

Operation 7.4 Operation 7.4.1

Operation monitoring system IMPORTANT! Do not overload engine.

If faults occur, investigate and solve them immediately to prevent major damage from oc­ curring!

The engine oil pressure is monitored during its operation.

If a fall in oil pressure is reported by the monitor, immediately shut down engine.

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Diesel Engines D856

Operation 7.5 Exhaust gas after treatment (SCR)

Simple schematic representation of the SCR system The SCR exhaust gas after treatment (selective catalytic reduction) relates to a technology for the conver­ sion or reduction of nitrogen oxides (NOx) in the exhaust gas, by means of the addition of a reducing agent (water-carbamide solution), in nitrogen (N2) and water (H2O).

7.5.1

Reducing agent

Terminology: S AdBlue® in Europe S DEF (Diesel exhaust fluid) in the USA IMPORTANT! Operation without reducing agent!

Statutorily prescribed exhaust gas values are not satisfied.

Operator becomes liable to prosecution.

For this reason: S Operate the system with reducing agent.

S Top up with reducing agent in good time.

Specification Reducing agent must satisfy the specifications detailed in the following.

Specifications: S DIN 70 070 S ISO 22241

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Diesel Engines D856

Operation Use / Handling CAUTION! Reducing agent can lead to injury to the eyes and to allergic skin reactions.

For this reason: S Avoid skin contact with reducing agent.

S Follow the manufacturer's instructions.

NOTE! In the event that reducing agent comes into contact with a painted surface or aluminium surface during filling: S Rinse down the affected surface immediately with water.

IMPORTANT! The mixing of special additives and thinning of the reducing agent (e.g. with tap water) is not permissible.

If the statutorily prescribed exhaust gas values are not adhered to: Destruction of the exhaust gas after treatment system will result.

For this reason: S Do not mix or thin reducing agent with special additives.

S Make sure that no dirt gets into the reducing agent.

S Do nor fill fluids and lubricants into the reducing agent tank.

S Do not fill reducing agent into the diesel fuel tank.

NOTE! The filling neck diameter of the reducing agent tank is smaller than that of the diesel fuel tank.

IMPORTANT! If diesel fuel is filled into the reducing agent tank, or vice versa: S Do not start the diesel engine.

S Contac Liebherr customer service.

The reducing agent must remain absolutely pure.

If, for example, during a repair the reducing agent is pumped from the tank, this must no longer be used, since the purity of the liquid is no longer guaranteed.

Disposal Dispose of reducing agent in an environmentally correct manner. For the procedure see the chapter "Dis­ posal of old substances".

Suitability for storage / Temperature resistance See manufacturer's documentation.

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Diesel Engines D856

Operation Availability Reducing agent can be obtained at filling stations, service stations or from the manufacturer and dealers.

You can also find outlet locations in Europe at www.findadblue.com For the procurement of reducing agent in the USA, please refer to Liebherr Newport News, VA, (757) 245-5251, info.lme@liebherr.com or www.discoverdef.com.

Consumption The consumption of reducing agent by the diesel engine depends on the use of the vehicle. Filling is not maintenance-dependent. The filling level of the reducing agent tank is indicated on a tank display in the equipment compartment. For reference information on filling see manufacturer's documentation.

7.5.2

Inspection and warning lamps

The various conditions of the SCR system are displayed to the operator through illumination of the corre­ sponding display lamps.

Inspection and warning lamps Lamp

Designation

Meaning

Remedy

Fault on exhaust gas after treat­ ment system or reducing agent tank level unsatisfactory

Top up with reducing agent and/or consult Liebherr customer service

MIL Lamp (Malfunction Indi­ cator Lamp)

MIL Lamp (used with LWE)

DEF Lamp

7.5.3

Warning and fault function strategies

The SCR system is monitored by a diagnostic system. When the diagnostic system detects a fault, for ex­ ample filling level of the reducing agent tank is unsatisfactory, poor quality of reducing agent, fault on an SCR component or a manipulation of the SCR system, a warning and fault strategy is activated.

The warning and fault strategy depends on the individual statutory requirements (exhaust regulations in accordance with EU Stage IIIB or in accordance with US EPA/CARB Tier4i) and depending on the use/ equipment application of the diesel engine.

The various warning and fault function strategies are represented in the following tables.

55

Diesel Engines D856

Operation Strategies for EU (Stage IIIB) application Application

Display indication

System status

Restriction

MIL off

DEF yellow

Stationary applica­ tions, mobile cranes (OW)

DEF Level < 20% or fault function exhaust gas after treatment system No restriction 0 h ­ 50 h

Signal tone

MIL yellow

DEF red

DEF Level < 10% or fault function exhaust gas after treatment system No restriction from 50 h

Signal tone

MIL off

DEF yellow

On-road applica­ tions, mobile cranes (UW)

DEF Level < 20% or fault function exhaust gas after treatment system No restriction 0 h ­ 50 h

Signal tone

MIL yellow, flashing DEF Level < 10% or fault function exhaust gas after treatment system No restriction DEF yellow, flashing from 50 h

Signal tone

56

Diesel Engines D856

Operation Application

Display indication

System status

Restriction

MIL off

DEF yellow

Off­road applica­ tions

DEF Level < 20% or fault function exhaust gas after treatment system No restriction 0 h ­ 50 h

Signal tone

MIL yellow

DEF red

DEF Level < 10% or fault function exhaust gas after treatment system No restriction from 50 h

Signal tone

57

Diesel Engines D856

Operation Strategies US-EPA/CARB (Tier4i) Application

Display indication

System status

Restriction

MIL off

DEF yellow

DEF Level < 20% or fault function - exhaust gas No restriction after treatment system 0 min ­ 60 min

Signal tone

MIL yellow

DEF yellow

Stationary applications, mobile cranes (OW)

DEF Level < 15% or fault function - exhaust gas Torque limitation at 80% after treatment system 60 min ­ 180 min

Signal tone

MIL yellow

DEF red

DEF Level < 10% or fault function - exhaust gas Torque limitation at 20% after treatment system 180 min ­ 210 min

Signal tone

MIL red

DEF red

Signal tone

58

DEF Level < 5% or fault function - exhaust gas after treatment system from 210 min

Torque limitation at 20%

Diesel Engines D856

Operation Application

Display indication

System status

Restriction

MIL off

DEF yellow

DEF Level < 20% or fault function - exhaust gas No restriction after treatment system 0 min ­ 60 min

Signal tone

MIL yellow, flashing

DEF yellow

On-road applications, mobile cranes (UW)

DEF Level < 15% or fault function - exhaust gas Vehicle speed maximum after treatment system 45 mph 60 min ­ 180 min

Signal tone

MIL yellow, flashing

DEF yellow, flashing

DEF Level < 10% or fault function - exhaust gas Vehicle speed maximum after treatment system 5 mph 180 min ­ 210 min

Signal tone

MIL yellow

DEF yellow, flashing

DEF Level < 5% or fault function - exhaust gas after treatment system from 210 min

Vehicle speed maximum 5 mph

Signal tone

59

Diesel Engines D856

Operation Application

Display indication

System status

Restriction

MIL off

DEF yellow

DEF Level < 20% or fault function - exhaust gas No restriction after treatment system 0 min ­ 60 min

Signal tone

MIL yellow

DEF yellow

DEF Level < 15% or fault function - exhaust gas Torque limitation at 80% after treatment system 60 min ­ 180 min

Signal tone Off­road applications

MIL yellow

DEF red

DEF Level < 10% or fault function - exhaust gas Torque limitation at 20% after treatment system 180 min ­ 210 min

Signal tone

MIL red

DEF red

Signal tone

60

DEF Level < 5% or fault function - exhaust gas after treatment system from 210 min

Torque limitation at 20%

Diesel Engines D856

Operation

NOTE! The restrictions do not take place suddenly, but via a ramp.

DANGER! Minimal vehicle speeds for on-road applications, mobile cranes (UW)!

Traffic obstacles/increased danger of accident For this reason: S Observe display indication.

S Top up with reducing agent in good time or consult Liebherr customer service.

61

Diesel Engines D856

Operation

62

Diesel Engines D856

Maintenance and Care 8

Care and Maintenance

8.1 Prerequisite Before commencing work, read and adhere to the General Safety Instructions and the Safety Instructions in this chapter.

Follow the instructions unconditionally and proceed with care and attention, in order to avoid accidents and injury to persons and damage to property.

Personal Protective Equipment The following protective equipment must be worn: S S S

Protective Clothing Safety Shoes Safety Gloves

8.2 Safety instructions Personnel S

The maintenance actions on the diesel engine detailed in the operating instruction must only be carried out by trained specialist personnel.

Ground rules WARNING! Risk of injury due to incorrectly executed maintenance!

Improper maintenance can case serious injuries or considerable property damage.

For this reason: S Ensure that the engine cannot be started be unauthorised persons.

S Perform all maintenance steps in accordance with the instructions in these Operating In­ structions.

S Ensure adequate work space before starting any work.

S Make sure work space is kept clean and orderly! Any unused parts or components lying around are potential sources of accidents.

WARNING! Risk of injury caused by maintenance work!

Before performing any maintenance work the engine must be set into the maintenance po­ sition if nothing else is explicitly stated.

For this reason: S The engine must be shut down.

S The engine must have cooled off.

S The battery main switch must be switched off and the ignition key removed.

63

Diesel Engines D856

Maintenance and Care

IMPORTANT! S Use only approved Fuels, Lubricants and Coolants (see chapter 12).

NOTE! Coolant S Antifreeze and mixtures of anti-corrosion, antifreeze and water are to be treated as ha­ zardous waste. When disposing of used coolants adhere to the regulations of the relevant local authorities.

Engine Oil S Make absolutely sure that no oil gets into the sewage system or soaks into the ground − Risk of contaminating drinking water!

Carefully collect used oil and properly recycle.

When handling used oil, observe the safety measures to protect your health.

Filter Elements S Filter elements such as for oil and fuel must be handled as special wastes and properly disposed of. Observe the regulations of the local authorities.

Batteries S Used batteries contain hazardous substances. Batteries must be taken back by the dis­ tributor and properly disposed of or be taken to a place of collection. Never dispose of used batteries in the household refuse.

Please also observe the country-specific regulations.

64

Diesel Engines D856

Maintenance and Care 8.3 Maintenance Schedule All of the maintenance work listed in the Operating Instructions must be performed at intervals according to the maintenance schedule.

The maintenance plan is prepared by the engine manufacturer Liebherr.

special intervals

every 2000

every 1000

every 500

every 50

every 10

on delivery

Maintenance/inspection based on operating hours

WORK TO BE CARRIED OUT by maintenance personnel n One-off activity l Repetition interval F as required d annually, at the start of the cold time of year

by authorised specialist per­ sonnel j One-off activity m Repetition interval G as required

diesel engine D

D

m m m

Check oil level (or after every 3rd filling of the tank)

D

D

m m m

Visual check (sealing, contamination, damage)

m m m

Check the diesel engine brake valve

m m m

Replace the diesel engine oil (at least once per year): CAUTION! Only E6 diesel engine oil should be used.

Difficulty factors: See lubrication and operating substances

m m m

Replace oil filter (at least once per year)

m m m

Check condition of belt drive and if necessary replace / check and if ne­ cessary adjust tension of V-ribbed belt

j m m

Check the intake and exhaust system for condition, secure fixing and se­ aling 3000 h

m m

Grease the starter gear ring on the flywheel Check the oil pan, engine mounting and diesel engine consoles for cor­ rect seating

d

Check flame glow plug system Cylinder head valves

j m m

Check / adjust valve clearance Cooling system

D

D

m m m

Check coolant level

m m m

Check cooling and heating system for sealing and condition

m

d

Check corrosion and frost protection concentration in the coolant

3000 h

Replace coolant

6000 h

Replace rotary seals and coolant pump bearing Fuel system

D

D

m m m

Check water separator on the fuel pre-filter and drain off water if ne­ cessary

m m m

Drain water and reside in fuel tank

m m

Replace fuel prefilter (or in the case of poor performance)

m m

Replace fuel fine filter

G

Vent fuel system

65

Diesel Engines D856

Maintenance and Care

special intervals

every 2000

every 1000

every 500

every 50

every 10

on delivery

Maintenance/inspection based on operating hours

WORK TO BE CARRIED OUT by maintenance personnel n One-off activity l Repetition interval F as required d annually, at the start of the cold time of year

by authorised specialist per­ sonnel j One-off activity m Repetition interval G as required

Air filter D

D

m m m

Check air filter vacuum indicator

D

m m m

Clean air filter dust extraction valve

G

Replace dry air filter - main element (in accordance with maintenance indicator / annually)

G

Replace dry air filter safety element (on every 3rd replacement of the main element / annually) Electrical system

j m m

Check batteries and cable connections

j m m

Check control unit mounting for condition

j m m

Check sensor systems, actuators, cable supports and plugs for condition SCR­System

m4500 h Replace the foam and filter element of the SCR carbamide pump (at least every 2 years)

66

Diesel Engines D856

Maintenance and Care 8.4 Maintenance work 8.4.1

Engine change WARNING! Risk of scalding!

Engine oil is hot.

For this reason: S Touch oil drain plugs only when wearing protective gloves.

NOTE! At every engine oil change replace oil filter elements.

Drain engine oil Drain the engine oil while the diesel engine is warm from operation.

1. Loosen oil filter cover (1) and unscrew by 2-3 turns.

Engine oil will now flow out of the oil module and into the oil pan.

NOTE! When carrying out an oil change use a container with adequate ca­ pacity (at least 60 litres), so that the oil does not overflow.

2. Place the container under the drain valve.

3. Unscrew the locking cap on the drain valve (1).

4. Screw the drain hose onto the drain valve (1).

5. Allow the engine oil to drain off.

6. Unscrew the drain hose from the drain valve (1).

7. Screw the locking cap back onto the drain valve (1).

67

Diesel Engines D856

Maintenance and Care Change Oil Filter Element 1. Unscrew and remove oil filter cover (1) along with O-ring (2) and oil filter element (3).

2. Remove oil filter element (3) and O-ring (2) from oil filter cover (1).

3. Clean oil filter cover (1).

4. Install new O-ring (2) onto oil filter cover (1).

5. Insert new oil filter element (3) into oil filter co­ ver (1).

6. Insert the oil filter cover (1) with oil filter element (3) into the oil module and tighten.

Tightening torque . . . . . . . . . . . . . . . . . . . . 40-50 Nm

68

Diesel Engines D856

Maintenance and Care Fill with engine oil IMPORTANT! Component damage caused by over filling!

Engine damage can occur if engine oil is filled to above the max. mark on the oil dipstick.

For this reason: S Do not fill above the max. notch on the oil dipstick.

MAX MIN

1. Remove cap (1).

2. Slowly fill engine oil into the filler neck.

For oil filling quantity, see “Technical Data“, page 112.

3. Reinstall cap (1).

IMPORTANT! Components can be damaged due to no oil pressure!

After 10 seconds the running en­ gine must cause the oil pressure to build.

For this reason: S Observe oil pressure indicator.

S Check oil pressure and check for leaks.

S If no oil pressure builds up, immediately shut down engine.

S Determine cause and rectify pro­ blem.

4 Start engine and let it run for a few minutes at low speed.

5. Shut down the engine.

6. Check engine oil level after 20 minutes.

69

Diesel Engines D856

Maintenance and Care Check Engine Oil Level NOTE! Check the oil level with the engine horizontal, approx. 20 minutes after shutting down the machine.

1. Pull out oil dipstick (1).

2. Wipe off oil dipstick (1) with a lint-free, clean cloth.

3. Reinsert the oil dipstick (1) all the way.

4. Pull out oil dipstick (1) again and check oil level.

The oil level should be between both of the marks on the dipstick and should never drop below the lower mark.

5. Reinsert the oil dipstick (1) all the way.

If the oil level is too low, refill with new oil.

MAX MIN

8.4.2

Check the oil pan, engine mounting and engine console for correct seating

1. Examine the oil pan for correct seating, tighten the screws if necessary.

2. Examine the engine consoles and engine mounting for condition and correct seating, tigh­ ten the screws if necessary.

70

Diesel Engines D856

Maintenance and Care 8.4.3

Check the intake and exhaust system for condition, check sealing

1. Check the intake pipes between the air filter and the diesel engine for condition, sealing and correct sea­ ting.

2. Check the exhaust pipelines for condition, sealing and correct seating.

8.4.4

Check the valve of the diesel engine brake

1. Check and grease the components of the ac­ tuating cylinder.

2. Actuate the brake valve.

Make sure, that the valve returns correctly to its initial position after actuation.

Sticking/catching of the valve leads to overheating of the diesel engine and engine damage as a consequence.

8.4.5

Check the flame start system

The flame start system is on the left side of the diesel engine.

To examine the flame start system above 20° C the temperature disconnect can be deactivated, in that the tag connector is withdrawn from the Temperature sensor. With the temperature sensor disconnected the system can then be examined with the engine heated up.

In the case of faults in the system, this should first be checked for electrical function.

Checking the flame function DANGER! Danger of fire and explosion!

Fuel can escape uncontrolled.

For this reason: S Do not smoke!

S Avoid open fire!

1. Place a collector container under the diesel en­ gine.

2. Remove the cable from the temperature sensor (1).

3. Observe the flame glow plug (2) with the sys­ tem switched on and the diesel engine running at low speed, directly through the intake pipe.

71

Diesel Engines D856

Maintenance and Care The flame must be clearly formed at low speed and burning strongly, or if direct sighting is not possible, the intake pipe in the vicinity of the flame glow plug must be perceptibly warm.

Check glow function 1. Remove the cable from the temperature sen­ sor.

2. Remove the flame glow plug and connect elec­ trical cable.

3. Set the starter switch to drive, so that the con­ trol light comes on (for procedure see user do­ cumentation).

The flame glow plug glows red after the end of the pre-glow (50 to 65s) on the heating coil.

If the heating coil on the flame glow plug does not glow: 4. Replace the flame glow plug or inspect the flame start automatic relay and replace if ne­ cessary.

Installation and removal of the flame glow plug Removal of flame glow plug 1. Disconnect the electrical cable (2) and fuel line (3).

2. Loosen the lock nut (1) and remove the flame glow plug from the intake pipe.

To install the flame glow plug 1. Coat the flame glow plug on its thread with se­ aling compound Hylomar SQ 32 M, Omnvisic 1050 or Reinzoplast and screw it into the intake pipe.

2. Align the flame glow plug with the fuel pipe line.

3. Screw on the fuel pipe line (3) and tighten.

4. Tighten the lock nut (1) on the flame glow plug to 25 Nm and connect the electrical cable (2).

72

Diesel Engines D856

Maintenance and Care Check the solenoid valve 1. Unscrew the fuel pipeline (3) on the flame glow plug (1).

2. Start the diesel engine Fuel flows from the fuel pipeline.

3. With the diesel engine running warm the fuel flow stops.

If no fuel appears, or if the fuel flow does not stop with the diesel engine running: 4. Replace the solenoid valve (2); when replacing it note the direction of flow indicated by an ar­ row and fit new gaskets.

73

Diesel Engines D856

Maintenance and Care 8.4.6

Cleaning fuel pre­cleaner DANGER! Fire hazard caused by uncontrolled fuel leakage When opening the fuel system, fuel can leak out uncontrolled.

For this reason: S Work carefully.

S Do not spill any fuel.

1. Close the shut-off valves between the diesel engine and the tank.

2. Fit the drain hose to the connection of the drain screw (1).

3. Unscrew the drain screw (1) a maximum of 2 turns and allow fuel to run out into a suitable container.

4. Tighten the drain screw (1).

5. Unscrew the filter housing (3).

6. Remove the O-ring (1).

7. Wash out the filter housing (3) and strainer (2) in clean diesel fuel and blow through with com­ pressed air.

8. Screw the filter housing (3) with strainer (2) and new O-ring (1) onto the fuel pre-cleaner hou­ sing.

9. Tighten filter housing (3).

Tightening torque . . . . . . . . . . . . . . . . . . . . . . . 10 Nm 10.Bleed fuel prefilter.

Bleed Fuel Prefilter 1. Open the shut-off valves between the diesel engine and the tank.

2. Unscrew plunger (1) of the hand pump.

3. Actuate the plunger (1) of the hand pump, until the bypass valve of the high-pressure pump is heard to open.

4. Screw the plunger (1) back on the hand pump and tighten.

5. Check fuel prefilter for leaks.

74

Diesel Engines D856

Maintenance and Care 8.4.7

Drain fuel filter - condensation water DANGER! Fire hazard caused by uncontrolled fuel leakage When opening the fuel system, fuel can leak out uncontrolled.

For this reason: S Work carefully.

S Do not spill any fuel.

1. Fit the drain hose to the drain screw fitting (1) 2. Unscrew the drain screw (1) a maximum of two turns and allow the condensation water to drain out into a suitable container.

3. Allow the condensation water to run off until pure fuel emerges.

4. Tighten the drain screw (1).

75

Diesel Engines D856

Maintenance and Care 8.4.8

Change fuel filter insert DANGER! Fire hazard caused by uncontrolled fuel leakage When opening the fuel system, fuel can leak out uncontrolled.

For this reason: S Work carefully.

S Do not spill any fuel.

1. Unscrew the filter cap (1) until the O-ring (2) is visible.

The fuel runs from the filter into the tank via the return line.

2. Unscrew the filter cap (1) with O-ring (2) and pull out the filter element (3).

3. Clean filter cap (1).

4. Install new O-ring (2) onto filter cap (1).

5. Insert new filter element (3) in the filter cap (1).

6. Screw on the filter cap (1) with O-ring (2) and filter element (3) and tighten.

Tightening torque . . . . . . . . . . . . . . . . . . . . . . . 25 Nm 7. Bleed fuel system, see page 77.

76

Diesel Engines D856

Maintenance and Care 8.4.9

Vent fuel system DANGER! Fire hazard caused by uncontrolled fuel leakage When opening the fuel system, fuel can leak out uncontrolled.

For this reason: S Work carefully.

S Do not spill any fuel.

1. Unscrew plunger (1) of hand pump.

2. Actuate the plunger (1) of the hand pump, until the bypass valve of the high-pressure pump is heard to open.

3. Screw the plunger (1) of the hand pump back in and tighten.

4. Check fuel system for leaks.

77

Diesel Engines D856

Maintenance and Care 8.4.10 Check the water separator on the fuel prefilter and drain off water WARNING! Open fire!

Fire and explosion.

For this reason: S During maintenance and inspection work on the fuel system do not use open fire or lights.

S Carry out maintenance and inspection work exclusively with the diesel engine switched off.

NOTE! Have a container to hand with the necessary capacity.

NOTE! The arrangement of the fuel prefilter with water separator and manual fuel priming pump varies depending on the diesel engine and equipment version.

Check the water separator of the fuel prefilter.

With water in the water separator: 1. Position the collector container under the water separator.

2. Unscrew the vent screw (1) two turns (anticlockwise).

3. To open the shut-off valve, pull out the blue handle (2) and at the same time rotate it through 90° anti-clockwise.

Wait until the water has run out.

4. To close the shut-off valve rotate the blue handle (2) through 90° clockwise (The handle latches back into position on its own).

8.4.11 Vent the fuel prefilter 1. Rotate the marking (2a) „PU“ in the direction of the arrow (anti-clockwise).

2. Actuate the manual supply pump (2b) until bub­ ble-free fuel emerges at the vent screw (1).

3. Close the vent screw.

Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . 6 Nm 4. For starting the diesel engine rotate the mar­ king (2c) in the direction of the arrow (clock­ wise).

78

Diesel Engines D856

Maintenance and Care 8.4.12 Replace fuel prefilter element WARNING! Open fire!

Fire and explosion.

For this reason: S During maintenance and inspection work on the fuel system do not use open fire or lights.

S Carry out maintenance and inspection work exclusively with the diesel engine switched off.

WARNING! Dirt!

Destruction of Common Rail System.

For this reason: S Take care that no dirt gets onto the clean side of the filter.

S Leave residual diesel fuel in the filter housing.

S Do not reuse fuel fine filters.

S Follow the special instructions for operation on the Common Rail System, see chapter „Safety instructions“ NOTE! Have a container to hand with the necessary capacity.

NOTE! The arrangement of the fuel prefilter with water separator and manual fuel priming pump varies depending on the diesel engine and equipment version.

1. Close fuel shut-off valve.

2. Place a collector container under the fuel pre­ filter.

3. Open fuel shutoff valve.

4. Unscrew the screws (2) and remove the cover (3) with gasket (4).

5. Remove the fuel prefilter element (5) together with the spring cassette (7).

6. Dispose of the fuel prefilter element (5).

7. Install new fuel prefilter element (5).

8. Check gasket (4), replace if necessary and re­ assemble in the reverse sequence.

9. Open the fuel shut-off valve and vent the fuel system.

79

Diesel Engines D856

Maintenance and Care 8.4.13 Check cooling and heating system for sealing and condition DANGER! Risk of burns!

Hot radiator/cooler parts and hot coolant.

For this reason: S Carry out maintenance and inspection work on the cooling system exclusively when the diesel engine has cooled down.

S Wear protective equipment.

NOTE! If a lack of sealing is established in the cooling system, do not start the diesel engine before eliminating the fault.

1. Check the radiator, coolant pump and the heat exchanger for the heating system for correct sealing.

2. Check all pipes and hoses of the cooling and heating system for correct sealing, undamaged condition, freedom from chafing and prescribed mounting.

3. Check the radiator for external soiling. The lamellae must not be clogged with dirt.

8.4.14 Replace rotary seals and coolant pump bearing.

Replace coolant pump in accordance with procedure, see Repair instruction - Diesel engine.

80

Diesel Engines D856

Maintenance and Care 8.4.15 Replace coolant Drain coolant WARNING! Risk of scalding!

The cooling system is under pressure and the coolant is hot.

For this reason: S First allow the engine to cool.

NOTE! When draining, do not spill the coolant. No coolant must ingress into the soil or into sources of water. Otherwise the environment will be damaged.

1. Open cap at filler neck of expansion reservoir.

NOTE! When draining the coolant use a container with adequate capacity (at least 120 litres), so that the coolant does not overflow.

2. Unscrew drain plug (1) with O-ring from the oil module.

3. Then remove the locking cap on the filler neck of the expansion tank.

4. Drain coolant.

5. Screw drain plug (1) with new O-ring back into the oil module and tighten.

Tightening torque . . . . . . . . . . . . . . . . . . . 80-90 Nm 6. Screw the locking cap back onto the filler neck of the expansion tank.

81

Diesel Engines D856

Maintenance and Care Fill with coolant NOTE! When filling, do not spill the coolant. No coolant must ingress into the soil or into sources of water. Otherwise the environment will be damaged.

The diesel engine cooling system must be filled with an antifreeze and a corrosion inhibitor, see chapter 12.

Coolant must be filled in accordance with the filing instruction of the vehicle manufacturer.

Take care, that the mixing ratio “Water-antifreeze" is restored.

1. Fill cooling fluid slowly (max. 10 ltr./min.).

2. After a short period of running of the engine, check the coolant level again.

82

Diesel Engines D856

Maintenance and Care 8.4.16 Check the concentration of the corrosion inhibitor in the coolant Check corrosion inhibitor concentration DANGER! Danger of burning and scalding!

Hot coolant.

For this reason: S Before opening the filler cap, allow the diesel engine to cool.

The coolant must contain at least 50 Vol.% of corrosion inhibiting antifreeze over the whole year, but not more than 60 Vol.%. A coolant with 50 Vol.% corrosion inhibiting antifreeze corresponds to a frost protec­ tion of around -37° C. 1. Carefully open the locking cap on the filler neck.

2. Extract the coolant sample and analyse it using a suitable test method.

If the analysis indicates low frost protection: 3. Correct the mixing ratio of the corrosion inhibitor in the coolant.

Correct the corrosion inhibitor antifreeze concentration IMPORTANT! Proportion of corrosion inhibitor antifreeze in the coolant too high!

The diesel engine can overheat and may become damaged.

For this reason: S Do not top up to more than 60% corrosion inhibiting antifreeze.

1. For coolant filling quantity see documentation of the vehicle manufacturer.

If the corrosion inhibiting antifreeze concentration is too low: 2. Drain off coolant and top up with corrosion inhibiting antifreeze in accordance with the calculation formula.

Calculation formula - Top up quantity of corrosion inhibitor antifreeze example 29 Vol.% (corresponds to -15° C)

83

Diesel Engines D856

Maintenance and Care 8.4.17 Use of corrosion inhibitor without frost protection Use of DCA 4 1. Take coolant sample and analyse with CC 2602 M Fleetguard test set.

If the analysis does not indicate DCA 4 concentration between 0.6 and 1.06 units per litre: 2. Correct the mixing ratio, see manufacturer's information.

Use of water-soluble Corrosion inhibitor S S S S

Caltex XLI Delo XLI Texaco XLI Havoline XLI

The mixing ratio must always have a value of 2.8 +/- 0.9 % Brix. This corresponds to 5-10 % corrosion inhi­ bitor and 95-90 % water.

1. Take a coolant sample and analyse with refractometer 2710 from the firm Gefo.

Check mixing ratio with refractometer

(1)

Refractometer Gefo 2710

(2)

Eyepiece

Measuring method: 1. Clean cover and prism carefully.

2. Place 1-2 drops of the coolant sample on the prism.

3. Close the flap (This causes the fluid to be distributed).

4. With the eyepiece (2) against a bright background, view and adjust the scale for sharpness.

5. Visual sharpness can be adjusted by rotation of the eyepiece (2).

6. Read off the Brix-values on the blue dividing line in the eyepiece (2).

84

Diesel Engines D856

Maintenance and Care Table for determining the top up quantity based on the example of 1% Brix

(1) (2)

Corrosion inhibitor top up quantity (Litres) Ledger lines

(3) (4)

Refractometer reading in % Brix Coolant quantity (Litres) in the cooling system

If a value of 1 % Brix is measured in the cooling system, then one travels along the ledger line (2) (starting from the measured value (1) Brix) and going to the left and under to the vertical line showing coolant quan­ tity in the cooling system (4) (50 Litres) and from this point horizontally outwards to the left (2.4 Litres pure corrosion inhibitor (1)). This gives that top up quantity of the pure corrosion inhibitor (1) that must be added, in order to return to the required value of 2.8 Brix.

To restore the correct mixing ratio the (previously) determined quantity, not less, must be drained from coo­ ling system.

1. Fill with the determined quantity of pure corrosion inhibiting antifreeze.

2. To reach the required coolant level, fill the remainder with the previously drained off coolant.

85

Diesel Engines D856

Maintenance and Care 8.4.18 Greasing the starter ring gear on the flywheel NOTE! When greasing, take care that the sensor ring gear (1) remains free from grease.

1. Remove the maintenance cover from the fly­ wheel housing.

2. Grease the starter ring gear (2) 3. Refit the maintenance cover.

8.4.19 Check the batteries and cable connections Check the batteries and cable connections in accordance with the approved procedure, see documentation from vehicle manufacturer.

8.4.20 Check the control unit mounting for condition NOTE! In the case of damaged mountings, do not start the diesel engine and replace all moun­ tings.

1. Remove 'kick board' (if fitted).

2. Check check control unit mounting for damage and correct seating.

8.4.21 Check sensors, actuators, cable mountings and plugs for condition NOTE! In the event of damage to cable connections, cable harness or sensors, do not start the diesel engine and replace defective parts.

1. Check all sensors, actuators, cable connections and plugs for correct seating and condition.

2. Check all cables and cable harness for undamaged condition, freedom from abrasion and specified in­ stallation.

8.4.22 Check the vacuum indicator of the air filter Check the vacuum indicator of the air filter according to the specified procedure, see documentation of the vehicle manufacturer.

8.4.23 Clean the dust discharge valve of the air filter Clean the dust discharge valve of the air filter according to the specified procedure, see documentation from the vehicle manufacturer.

86

Diesel Engines D856

Maintenance and Care 8.4.24 Replace the dry air filter main element For the dry air filter main element procedure, see procedure "Replace dry air filter-main element", in docu­ mentation from the vehicle manufacturer.

8.4.25 Replace dry air filter safety element For the dry air filter safety element replacement procedure, see documentation from the vehicle manufac­ turer.

8.4.26 Replace Poly-V belt Remove Poly-V belt WARNING! Risk of injury!

Poly-V belt tensioner is under tension For this reason: S Secure the Poly-V belt tensioner against undesired spring back.

1. Attach the tool (3) onto the Poly-V belt tensioner (2).

2. Rotate the Poly-V belt tensioner (2) clockwise and hold it.

3. Remove Poly-V belt (1).

4. Carefully release the Poly-V belt tensioner (2).

87

Diesel Engines D856

Maintenance and Care Install Poly-V belt CAUTION! Risk of injury!

Poly-V belt tensioner is under tension For this reason: S Secure the Poly-V belt tensioner against undesired spring back.

1. Rotate the Poly-V belt tensioner (2) in a clock­ wise sense and hold it.

2. Install Poly-V belt (1).

3. Carefully release the Poly-V belt tensioner (2).

4. Remove the tool (3) from the Poly-V belt tensioner (2).

8.4.27 Visual check (sealing, contamination, damage) 1. Visually inspect the diesel engine for correct sealing.

2. Check pipelines and hoses for sealing through visual inspection.

3. Check pipelines and hoses for undamaged condition, abrasion-free state and specified fixing.

8.4.28 Drain water and residue from fuel tank WARNING! Open fire!

Fire and explosion.

For this reason: S During maintenance and inspection work on the fuel system do not use open fire or lights.

S Carry out maintenance and inspection work exclusively with the diesel engine switched off.

Drain off water and residue in the fuel tank according to the specified procedure - see documentation from vehicle manufacturer.

When filling, keep the fuel level in the tank as high as possible, in order to avoid condensation as far as possible.

88

Diesel Engines D856

Maintenance and Care 8.4.29 Check valve clearance and adjust IMPORTANT! Engine damage can occur due to incorrectly adjusted valves For this reason: S Adjust the valves only when the engine is cold Technical Data Mounting bolts - Cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm Lock nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm Lock nut retainers EVB . . . . . . . . . . . . . . . . . . . . 45 Nm Adjustment dimension, retainers EVB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.6 mm Valve clearance, intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm Valve clearance, outlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm Special tools [1]

[2]

Engine cranking device S

Crank the diesel engine in combination with:

S

Gear wheel ratchet [2]

Gear wheel ratchet S

[3]

[4]

10017185

Cranking the diesel engine

Retainer S

Check valve and EVB clearance and adjust in conjunction with:

S S S S S S

Feeler gauge blade 0.5 [4] Feeler gauge blade 0.6 [5] Feeler gauge blade 0.8 [6] Valve adjuster key SW 14 [7] Valve adjuster key SW 21 [8] Torque wrench [9]

Feeler gauge blade 0.5 S

10017187

10665090

10665095

Check / adjust valve clearance

89

Diesel Engines D856

Maintenance and Care [5]

Feeler gauge blade 0.6 S

[6]

[7]

[9]

90

10450916

Adjust EVB clearance

Torque wrench S

11100491

Check / adjust valve clearance

Valve adjuster key SW 21 S

10665097

Check / adjust valve clearance

Valve adjuster key SW 14 S

[8]

Check and adjust EVB clearance

Feeler gauge blade 0.8 S

10665096

Adjust valve and EVB clearance

10450913

Diesel Engines D856

Maintenance and Care Remove cylinder head cover 1. Unscrew mounting bolts (1).

2. Remove cylinder head cover (2).

Install engine cranking device 1. Remove cover from flywheel housing/timing case.

2. Fit engine cranking device (1) to flywheel hou­ sing.

Rotate diesel engine to setting position A = Rocker arm in overlap B = Rocker arm free for the valve clearance adjustment 1. Crank diesel engine, until rocker arms are in overlap.

2. Adjust the free rocker arm in accordance with the table.

91

Diesel Engines D856

Maintenance and Care Check valve clearance - Intake valve 1. Slide in retainer [3] (4) with feeler gauge blade 0.5 [4] (2) between ball socket (1) and valve bridge (3) If the valve clearance is not 0.50 mm, the valve play must be adjusted.

Adjust valve clearance - Intake valve 1. Loosen lock nut (2) and adjuster screw (1).

2. Slide in retainer [3] (5) with feeler gauge blade 0.5 [4] (6) between ball socket (3) and valve bridge (4) 3. Screw in the adjuster screw (1), until the 0.5 mm feeler gauge blade [4] (6) is free to move with minimal resistance between the ball socket (3) and valve bridge (4).

4. Restrain the adjuster screw (1) with the valve adjuster key SW 14 [7].

5. Tighten the lock nut (2) with the torque wrench [9] to 45 Nm. 6. Check the setting again, if necessary repeat the adjustment procedure.

92

Diesel Engines D856

Maintenance and Care Check valve clearance of exhaust valve 1. Again, press down the valve bridge (2), to force out engine oil from the EVB piston (5) 2. Slide in retainer [3] (3) with feeler gauge blade 0.8 [6] (4) between ball socket (1) and valve bridge (2) If the valve clearance is not 0.8 mm, the valve play must be adjusted.

Bring the EVB piston into the setting position 1. Loosen the lock nut (2) and unscrew it several turns 2. By screwing in the adjuster screw (1) press the valve bridge (3) down again to the stop The engine oil must have completely escaped from the EVB piston (4) .

IMPORTANT! Danger of incorrect valve clearance For this reason: S The EVB piston must be fully pushed against the valve bridge

93

Diesel Engines D856

Maintenance and Care Adjust valve clearance - exhaust valve 1. Loosen the lock nut (3) 2. By screwing in the adjuster screw (2) press the valve bridge (6) down to the pressure point 3. Lock the valve bridge (6) in this position with the adjuster screw (1) 4. Slide in retainer [3] with feeler gauge blade 0.8 [6] (5) between ball socket (4) and valve bridge (6) 5. Screw in the adjuster screw (2) until the 0.8 mm feeler gauge blade [6] (5) is free to move with minimal resistance between the ball socket (4) and valve bridge (6).

6. Restrain the adjuster screw (2) with the valve adjuster key SW 14 [7].

7. Tighten the lock nut (3) with the torque wrench [9] to 45 Nm. 8. Check the setting again, if necessary repeat the adjustment procedure.

Check the setting dimension for EVB piston 1. Lightly press down the valve bridge (1).

2. Slide in retainer [3] (3) with feeler gauge blade 0.6 [5])(2) between retainer (4) and valve bridge (1) If the setting dimension is not 0.6 mm, the EVB clearance must be adjusted.

94

Diesel Engines D856

Maintenance and Care Adjust the clearance for EVB piston 1. Loosen the lock nut (2) 2. Screw out the adjuster screw (1) until the re­ tainer [3] (3) with feeler gauge blade 0.6 [5] (4) can slide in 3. Screw in the adjuster screw (1) with the in­ serted feeler gauge blade 0.6 [5] (4), until the valve bridge lies on the stop (as sensed by a noticeable increase in force) 4. Restrain the adjuster screw (1) with the valve adjuster key SW 21 [8].

5. Tighten the lock nut (2) with the torque wrench [9] to 45 Nm. 6. Check the setting again, if necessary repeat the adjustment procedure.

NOTE! The valve bridge must not move the exhaust valve on screwing in the adjuster screw.

Remove the engine cranking device 1. Remove cover from flywheel housing/timing case.

2. Fit engine cranking device (1) to flywheel hou­ sing.

95

Diesel Engines D856

Maintenance and Care Tightening sequence, cylinder head cover A = Intake side B = Exhaust side Adhere to the represented tightening sequence 1 to 18 for the mounting bolts in the following work step

Fit cylinder head cover 1. Check the gasket in the cylinder head cover (2), replace if necessary 2. Place the cylinder head cover (2) on the cy­ linder head 3. Screw in mounting bolts (1).

4. Tighten mounting bolts (1) to 10 Nm in ac­ cordance with the tightening sequence

96

Diesel Engines D856

Maintenance and Care 8.4.30 Check valve control timing NOTE! Valve timing must be checked with the correctly set valve clearance.

Technical Data Valve stroke for measurement process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm? Mounting bolts - Cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm Special tools [1]

Dial gauge S S S

[2]

[3]

[5]

10017187

Crank the diesel engine in combination with: Gear wheel ratchet [5]

Gear wheel ratchet S

10023965

Check Valve timing

Engine cranking device S S

10017185

Check Valve timing

Feeler S

[4]

Check valve timing in conjunction with: Gear wheel ratchet [2] Feeler [3]

Dial gauge holder S

10017187

10017185

Cranking the diesel engine

97

Diesel Engines D856

Maintenance and Care Remove cylinder head cover 1. Unscrew mounting bolts (1).

2. Remove cylinder head cover (2).

Install engine cranking device 1. Remove cover from flywheel housing/timing case.

2. Fit engine cranking device (1) to flywheel hou­ sing.

Turn diesel engine to TDC marking 1. Rotate flywheel with engine cranking device [226] (1) and gear wheel ratchet [227] in the engine direction of rotation, until the TDC mar­ king on the flywheel coincides with the TDC marking (2) Rocker arm cylinder 6 must be in the overlap posi­ tion.

Standing rocker arm cylinder 6 not in overlap posi­ tion, rotate flywheel 360° further up to the TDC marking.

98

Diesel Engines D856

Maintenance and Care Check valve stroke 1. Set up the dial gauge [1] (4) with feeler [3] (2) and dial gauge holder [2] (3) on valve head in­ take valve cylinder 3 2. Set dial gauge [1] (4) to zero.

3. Rotate the diesel engine further in the engine direction of rotation, until the dial gauge no longer moves In this position the correct valve stroke must be 11.30 - 11.70 mm .

Tightening sequence, cylinder head cover A = Intake side B = Exhaust side Adhere to the represented tightening sequence 1 to 18 for the mounting bolts in the following work step

99

Diesel Engines D856

Maintenance and Care Fit cylinder head cover 1. Check the gasket in the cylinder head cover (2), replace if necessary 2. Place the cylinder head cover (2) on the cy­ linder head 3. Screw in mounting bolts (1).

4. Tighten mounting bolts (1) to 10 Nm in ac­ cordance with the tightening sequence

Install engine cranking device 1. Remove cover from flywheel housing/timing case.

2. Fit engine cranking device (1) to flywheel hou­ sing.

100

Diesel Engines D856

Maintenance and Care 8.4.31 Replace the foam and filter element of the SCR carbamide pump Make sure, that: S A new foam and filter element is available.

S A new drain plug is available.

S A new sealing ring is available for the filter cover.

S A suitable collection container with the required capacity is available.

1. Disconnect the electrical connection.

2. Position the collector container under the SCR carbamide pump.

3. Open the vent screw (1).

4. Unscrew the drain screw (6).

5. Allow the residual reducing agent to drain off into the collector container.

6. Unscrew the filter cover (5) using a socket or pipe wrench.

7. Remove the filter element (3) and foam element (2) and dispose of these correctly, with environmental safety (see the chapter "Disposal of old/used substances“).

8. Remove old sealing ring (4).

9. Smear new sealing ring (4) with clean water or reducing agent and mount it on the filter cover (3).

10.Insert the new foam and filter elements (2) and (3) in the filter cover (5).

11.Slide the filter cover (5) with the inserted foam and filter elements (2) and (3) into the filter housing.

12.Tighten the filter cover (5) to 15 Nm. 13.Tighten the new drain screw (6) to 2.5 Nm. 14.Tighten the vent screw (1) to 1.5 Nm. 15.Check for leakage losses from the vent pump.

16.Reconnect the electrical connection.

17.Start the diesel engine.

18.Check the pump during the start sequence (priming) for lack of sealing.

NOTE! Has any leakage been detected?

S Do not start the diesel engine.

S Eliminate sources of leakage.

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Diesel Engines D856

Maintenance and Care

102

Diesel Engines D856

Faults 9

Faults

In the following chapter the possible causes of faults and the work required for their elimination are de­ scribed.

In the event of faults, which cannot be eliminated using the following information, the manufacturer of the complete plant should be consulted.

9.1 Prerequisite Before commencing work, read and adhere to the General Safety Instructions and the Safety Instructions in this chapter.

Follow the instructions unconditionally and proceed with care and attention, in order to avoid accidents and injury to persons and damage to property.

Personal Protective Equipment The following protective equipment must be worn: S S S

Protective Clothing Safety Shoes Safety Gloves

9.2 Safety instructions Personnel S

Engine faults may only be rectified by specially trained qualified personnel or by the manufacturer.

Ground rules WARNING! Risk of injury caused by improper rectification of faults!

Improper rectification of faults can case serious injuries or considerable property damage.

For this reason: S Ensure that the engine cannot be started be unauthorised persons.

S Ensure adequate work space before starting any work.

S Make sure work space is kept clean and orderly! Any unused parts or components lying around are potential sources of accidents.

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Diesel Engines D856

Faults 9.3 Fault table Fault

Possible cause

Engine does not start

D Fuel tank empty D Fuel valve shut off D Air in fuel system D Fuel lines unsealed, broken or blocked D Fuel filter/ -pre-cleaner blocked D Condensation in fuel D Air filter clogged D Exhaust clogged (exhaust back pressure too high) D Electric circuit interrupted

D Battery dead D Starter/solenoid switch defect D Injectors clogged D Valves do not close or are stuck D Crank assembly is externally blocked

Remedy

D Drain water from fuel filter and tank

D Set main switch to "on" D Set transmission shift lever to "N" D Replace faulty fuses D Repair any loose, corroded and broken wires and contacts D See further under "Starter" D Remove objects that interfere with the movement of the fan, power output, alternator, etc.

D Inner engine damage (piston seizure, possibly caused by water in fuel) Engine starts but does not reach idle speed or stalls

D Power take-off is on D Fuel filter clogged D Fuel grade does not meet the specifica­ tions or is contaminated D Air filter clogged

Engine does not start when warm, or only starts poorly

D Engine shutoff faulty D Insufficient compression in cylinder or more than 3-4 bar pressure difference between the cylinders

Engine does not start when cold, or only starts poorly

D Fuel filter clogged with paraffin

Uneven idling with warm engine, engine misfiring

D Air in fuel system D Fuel lines unsealed, broken or blocked D Fuel filter clogged D Lower idle speed is set too low D Valve clearance not OK D Injectors or injection lines leak D Turbocharger faulty D Insufficient compression in cylinder or more than 3-4 bar pressure difference between the cylinders

Engine speed fluctua­ tions during operation

104

D Too little fuel in tank D Air in fuel system D Tachometer faulty D Injectors faulty

D See "Chapter 12"

D Replace filter.

D Help from the manufacturer ser­ vice

Diesel Engines D856

Faults Fault

Possible cause

Poor performance

D Too much power is demanded from the engine than it can produce D Air in fuel system D Fuel filter/air filter clogged D Fuel grade does not meet the regu­ lations D Insufficient fuel supply D Oil level in oil pan too high

D Exhaust pipe blocked D Air intake pipe leaks D Turbocharger leaks or faulty D Insufficient compression in cylinder or more than 3-4 bar pressure difference between the cylinders D Rated speed incorrectly set D Exhaust gas after treatment system blocked

Remedy

D See "Chapter 12" D Fuel feed pump worn or faulty D Check whether the guide tube is correctly installed and the cor­ rect oil dipstick is being used D If coolant or fuel is discovered in the engine oil, check cylinder head gasket, cylinder liner gas­ ket and piston rings

D Contact Liebherr customer ser­ vice

Coolant temperature D Coolant level too low too high, loss of coolant D Air in coolant circuit D Cooler badly soiled, lamella clogged D V-belt for coolant pump not correctly tightened (slips) D Cap with work valves on expansion reservoir/radiator is faulty or leaks D Temperature display faulty D Coolant pump leaks, defective (bearing damage) D Thermostat faulty, does not open D Coolant lines leak, clogged or twisted Lube-oil pressure too low

D Oil level in oil pan too low D Engine temperature to high D Oil filter clogged D Oil pressure indicator faulty D Selected oil viscosity is inappropriate for D See "Chapter 12" ambient temperature (too thin) D Oil in oil pan is too thin (contains con­ densation or fuel) D Bearing heavily worn D Oil pump gears heavily worn D Safety valve in oil circuit faulty (does not close, spring is worn or broken)

Lube-oil pressure too high

D Engine cold D Selected oil viscosity is inappropriate for D See "Chapter 12" ambient temperature (too thick) D Oil pressure indicator faulty D Safety valve in oil circuit faulty (does not open) D Oil lines/oil ducts clogged

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Diesel Engines D856

Faults Fault

Possible cause

Remedy

Lube-oil consumption too high

D Lube-oil quality does not meet the regu­ lations D Oil level in oil pan too high

D See "Chapter 12" D Check whether the guide tube is correctly installed and the cor­ rect oil dipstick is being used D If coolant or fuel is discovered in the engine oil, check cylinder head gasket, cylinder liner gas­ ket and piston rings

D Oil separator valve defective D Leaks in lube-oil circuit especially at the turbocharger and oil cooler D Piston rings heavily worn D Valve stems heavily worn, bent Fuel consumption too high

D Fuel grade does not meet the regu­ lations D Fuel loss due to leaks in system D Valve seat leaks

Black smoke accom­ D Air filter clogged panied by loss of power D Air intake duct leading to turbocharger leaks D Exhaust clogged (exhaust back pressure too high) D Turbocharger faulty

D See "Chapter 12"

D Help from the manufacturer ser­ vice

D Intercooler or charge air lines blocked, or defective D Injector defect, coked Blue smoke

D Engine/coolant/intake air still too cold D Lube oil penetrates into combustion chamber (pistons/piston rings worn or piston rings broken) D Valve stem/guide worn D Overpressure in crankcase (crankcase ventilation system clogged)

White smoke

D Engine/coolant/intake air still too cold D Fuel tank empty D Air in fuel system D Fuel lines unsealed, broken or blocked D Coolant penetrates into combustion chamber (cylinder head/gasket leaks) D Fuel filter clogged D Fuel grade does not meet the regu­ lations D Injectors faulty

106

D See "Chapter 12"

Diesel Engines D856

Faults Fault

Possible cause

Remedy

Engine knocking

D Engine not at correct operating tempe­ rature

D Let engine warm to operating temperature before running at full load D Check thermostat

D Valve clearance not OK D Valves stick D Piston pin or crankshaft bearing loose D Piston ring broken Engine too "loud"

D Intake or exhaust pipe leaks D Timing gears worn, gear backlash too large D Valve clearance too large D Turbine and compressor impeller in tur­ bocharger dirty (rough running, out of balance) D Poly-V-belt slips

Starter

D Pinion gear does not D Battery has insufficient charge turn or turns slowly D Connection terminals loose, oxidised, poor earth connection D Starter terminals or carbon brushes have short to earth D Carbon brushes stick or have poor con­ tact D Pinion gear does not D Pinion or starter ring severely soiled or engage damaged D Pinion gear D Solenoid switch faulty engages, but stops D Overrunning clutch slips turning D Pinion gear conti­ D Starter switch faulty nues to turn after D Solenoid switch faulty starter switch is re­ leased D Pinion gear does not D Starter defect disengage after en­ gine starts

D Help from the manufacturer ser­ vice

Remedial action only by vehicle electrician or Manufacturer Ser­ vice

D Immediately shut down engine

107

Diesel Engines D856

Faults

108

Diesel Engines D856

Decommissioning and recommissioning 10

Decommissioning and recommissioning

10.1 Prerequisite Before commencing work, read and adhere to the General Safety Instructions and the Safety Instructions in this chapter.

Follow the instructions unconditionally and proceed with care and attention, in order to avoid accidents and injury to persons and damage to property.

Personal Protective Equipment The following protective equipment must be worn: S S S

Protective Clothing Safety Shoes Safety Gloves

10.2 Safety instructions Personnel S

The decommissioning and recommissioning of an engine must only be undertaken by trained specialist personnel.

Ground Rules WARNING! Risk of injury due to incorrect work!

Improper rectification of faults can case serious injuries and/or considerable damage to property.

For this reason: S Ensure that the engine cannot be started be unauthorised persons.

S Perform all operating steps in accordance with the information in these Operating Instruc­ tions.

S Ensure adequate work space before starting any work.

S Make sure work space is kept clean and orderly! Any unused parts or components lying around are potential sources of accidents.

109

Diesel Engines D856

Decommissioning and recommissioning 10.3 Recommissioning of decommissioned engines 10.3.1 Commissioning of non-preserved engines In addition to the work sequences for a preserved engine, the commissioning of non-preserved engines requires the following additional effort, depending on the possible deterioration in storage.

1. Combustion chamber endoscopy, involving the removal and replacement of the injectors.

Check on valves for mobility, check on valve clearance and adjusting if required.

Renewal of damaged / corroded parts.

2. Drain old engine oil from the engine and replace oil filter, fill with fresh approved engine oil.

3. Check cooling system for corrosion, test coolant for concentration and condition, in case of doubt re­ place the coolant. First clean coolant areas and if necessary remove/replace coolant pump and thermostats, renew the mechanical seals of the coolant pump and the thermostat inserts, pressure test cooling system.

4. Check clean air system, air filter and exhaust turbocharger or soiling and corrosion, if necessary clean or repair.

5. Clean fuel system, if necessary drain off old fuel. Clean filter / check / renew.

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Diesel Engines D856

Technical Data 11

Technical data

11.1 Dimensions and weight Specification Weight (dry) D856 A Variant A / B Variant C B Variant A / B Variant C C Variant A / B Variant C

Value

Unit

1085

kg

1535 1428

mm mm

770 839

mm mm

1143 1163

mm mm

11.2 Requirements at the installation location, space requirement Observe the information in the assembly instruction.

111

Diesel Engines D856

Technical Data 11.3 Engine data 11.3.1 D856 Engine model

D856

Design

Series

Operating principle

4-stroke-diesel with supercharging / charge cooling

Combustion system

Direct injection

Supercharging

Exhaust turbocharger with Intercooling

Number of cylinders

6

Bore

126 mm

Stroke

166 mm

Swept volume

12 419 cm3

Compression ratio

19 : 1

Firing order

1-5-3-6-2-4

Valve clearance (cold engine) Intake Exhaust

0.50 mm 0.80 mm

Valve timing Intake opens Intake closes Exhaust opens Exhaust closes

24° before TDC 12° after BDC 60° before BDC 30° after TDC

Fuel system High-pressure pump

Bosch CP 3.4

Injection system

Common Rail

Governor

Electronically controlled diesel injection

Injectors

8-hole nozzles

Engine lubrication

Forced-feed lubrication system

Oil change quantity (with filter)

42 l

Oil filter

Oil module with oil cooler and oil separator

Engine cooling system Coolant temperature

Liquid cooling 80-90°C, short-term 95°C permissible

Electrical equipment

112

Starter

24 V; 7 kW

Alternator

24 V; 110 A

Diesel Engines D856

Lubrication and Fuels, Lubricants and Coolants 12

Lubrication and Fuels, Lubricants and Coolants

12.1 Handling Lubrication and Fuels, Lubricants and Coolants The conscientious adherence to the rules for the handling of lubricants, fuels and coolants increases the life and reliability of the machine.

It is particularly important, that the stated intervals for the replacement of oils and lubricants and their quality are adhered to.

You will find the various information on prescribed intervals in the "Maintenance“ chapter under "Mainte­ nance and Inspection Plan“ You will find the various information on the execution of lubrication, checking levels and changing oils and lubricants in "Maintenance“ chapter under "Maintenance activities“ Observe the regulations relating to the environment and the rules for the handling of lubricants and other operating substances.

12.2 Precautions for protection of the environment S

Always comply with measures for the protection of the environment.

S

Observe country-specific regulations.

S

Before draining fluids, make sure you know and comply with the correct means for their safe disposal.

12.3 Disposal of used substances This includes old and used substances and hazardous waste such as: S S S S

Oils, lubricants and refrigerants from air conditioning equipment, etc.

Coolant Fuels Filters, oil filter cartridges, etc.

Procedure NOTE! Danger for health and the environment.

S Observe the country-specific regulations for the protection of the environment when dis­ posing of old substances.

S

Collect old materials and substances and store them in suitable separate containers.

S

Only dispose of old substances at official collection stations in an environmentally-friendly manner.

113

Diesel Engines D856

Lubrication and Fuels, Lubricants and Coolants 12.4 Diesel fuel 12.4.1 Specification Diesel fuel must satisfy the minimum requirements as stated in the specifications below.

Approved specifications: S DIN EN 590 S ASTM D 975 - 1D S15 and 2D S15

12.4.2 Sulphur content in diesel fuel Diesel fuels having a sulphur content in excess of 15 mg/kg (0.0015%) are not permissible.

12.4.3 Diesel fuel - Lubrication capability The lubrication capacity of diesel fuel must be a maximum 460 m in accordance with the HFRR (60) test (lubricity corrected "wear scar diameter" [1.4] at 60 °C).

A written confirmation by the fuel supplier must be available.

The process of incorporating the additive should be carried out by the supplier - in his capacity as the party responsible for the quality of the fuel. The addition of secondary lubricity additives by the customer is not recommended.

NOTE! Obtain written confirmation from the supplier.

12.4.4 Ignition quality A cetane number of at least 45 is required for fuel in accordance with ASTM D 975. A cetane number over 50 is preferable, particularly at temperatures lower than 0 °C (32 °F).

12.4.5 Diesel fuel at low temperatures (Winter operation) As outside temperatures drop paraffin crystals separate out, which causes the resistance to flow in the fuel filter to increase to the extent that an adequate supply of fuel to the diesel engine can no longer be gua­ ranteed.

WARNING! The admixing of petroleum or regular grade gasoline is not permitted for reasons of safety and on technical grounds.

For this reason: S Use special diesel fuels, which have an adequate flow behaviour when the machine is operated in an arctic climate.

S Use a starting aid device (e.g. fuel filter heating), if the outside temperature drops below -20 °C

114

Diesel Engines D856

Lubrication and Fuels, Lubricants and Coolants 12.5 Lube oil for diesel engines 12.5.1 Lube oil quality Today only high alloy lubricating oils are used in modern diesel engines.

These consist of base oils, to which additives are mixed.

The lube oil prescription for Liebherr diesel engines is based on the following specifications and regulations.

Item ACEA - Classification (Association des Construc­ teurs Européens de l'Automobile)

Specification E6, E9 E9, Caution: Note reduced oil change intervals

API - Classification (American Petroleum Institute)

CJ-4 Caution: Note reduced oil change intervals.

12.5.2 Lube oil viscosity The choice of lube oil viscosity is based on the SAE classification (Society of Automotive Engineers).

A decisive factor for the correct selection of the SAE class is the ambient temperature.

The selection of the SAE classification provides no information on the quality of a lube oil.

Too high a viscosity can lead to starting difficulties and too low a viscosity can impair lubricating efficiency.

The temperature ranges shown in the adjacent graphic are guidelines, these can be exceeded or unattained for short periods.

The following diesel engine oils are recommended for an ambient temperature from -20 °C (-4 °F) to 45 °C (113 °F): Liebherr Engine Oil 10W­40 low ash, Specifikation ACEA E6 The following diesel engine oils are recommended for an ambient temperature from -30 °C (-22 °F) to 30 °C (86 °F): Liebherr engine oil 5W­30 low ash, Specifikation ACEA E6

115

Diesel Engines D856

Lubrication and Fuels, Lubricants and Coolants 12.5.3 Lube oil change intervals Change intervals: See in "Maintenance and Inspection plan“ Oil changing depending on climate zone, sulphur content in the fuel and oil quality is in accordance with the following table.

If the stated operating hours (h) are not achieved in the year, the diesel engine oil and filter should be changed at least once per year.

Various difficulty factors (difficult conditions of use) change the maintenance interval.

Difficulty factors can be: S Frequent cold starts S Temperature of use If difficulty factors or difficult conditions of use apply, then the oil and filter change must be in accordance with the following table.

Oil quality

Difficulty factor CJ-4 E9

E6

conditions of use

Sulphur content in the fuel

Interval (h = Operating hours)

Climate normal down to -10 °C

up to 0.0015 %

250 h

500 h

Climate under -10 °C up to 0.0015 % (permanent temperature)

125 h

250 h

12.6 Coolant, Diesel engine 12.6.1 General recommendations Coolant is a mixture of water with additives for corrosion protection and corrosion/frost protection.

Coolant: S Can be mixed with the following named products.

S Can be obtained as a finished mixture.

The cooling system functions reliably exclusively under pressure. Keep the cooling system clean and sea­ led. The coolant locking and operating valves must function correctly. Always maintain the necessary coo­ lant level.

Corrosion inhibitor antifreeze approved by Liebherr: S Guaranteed adequate frost, corrosion and cavitation protection.

S Does not attack seals and hoses.

S Does not foam.

Coolants cause cavitation or corrosion damage in the cooling system, if they contain unsuitable corrosioninhibiting antifreeze or are incorrectly prepared. Heat-insulating deposits on heat transferring components lead to overheating and failure of the diesel engine.

Emulsified corrosion protection oils are forbidden.

116

Diesel Engines D856

Lubrication and Fuels, Lubricants and Coolants 12.6.2 Water (fresh water) Colourless, clear tap water, free from mechanical impurities, with the following restricted analytical values, is suitable.

Sea water, brackish water, brine and industrial waste water are unsuitable.

Value

Item Sum of the alkaline earths (water hardness)

0.6 mmol/dm3 up to 3.6 mmol/dm3 (3 to 20 °d)

pH value at 20 °C

6.5 to 8.5

Chloride ion content

Maximum 80 mg/dm3

Sulphate ion content

Maximum 100 mg/dm3

Ask for the water analyses by the relevant local authorities.

12.6.3 Coolant - Mixing ratio Coolant must contain at least 50% corrosion-inhibitor antifreeze the whole year round.

Outside temperature up to

Mixing ratio Water %

Corrosion-inhibitor antifreeze %

-37 °C (-34.6 °F)

50

50

-50 °C (-58 °F)

40

60

IMPORTANT! Proportion of corrosion-inhibitor antifreeze in the coolant too high!

The diesel engine can overheat and may become damaged.

For this reason: S Do not top up to more than 60% corrosion inhibiting antifreeze.

117

Diesel Engines D856

Lubrication and Fuels, Lubricants and Coolants 12.6.4 Approved corrosion inhibiting antifreeze.

Product designation

Manufacturer

Liebherr Antifreeze Concentrate

Liebherr

NOTE! If Liebherr Coolant is not available on site: S Use coolant, which corresponds to the "Coolant specification for Liebherr diesel engines 10652041" (consult customer service).

NOTE! The mixing of different corrosion-inhibiting antifreeze can lead to a deterioration in the characteristics of the coolant.

S Do not combine different products!

S Coolant containing silicate and silicate-free coolant must never be mixed, since this can lead to damage to the cooling system!

12.6.5 Approved, ready-mixed corrosion-inhibiting antifreeze Product description

Manufacturer

Liebherr Antifreeze Mix

Liebherr

NOTE! If Liebherr Coolant is not available on site: S Use coolant, which corresponds to the "Coolant specification for Liebherr diesel engines 10652041" (consult customer service).

NOTE! The mixing of different corrosion-inhibiting antifreeze can lead to a deterioration in the characteristics of the coolant.

S Do not combine different products!

S Coolant containing silicate and silicate-free coolant must never be mixed, since this can lead to damage to the cooling system!

118

Diesel Engines D856

Lubrication and Fuels, Lubricants and Coolants 12.6.6 Approved corrosion inhibitors without frost protection In exceptional cases and in the event of ambient temperatures above freezing point, for example in tropical regions, in which demonstrably no approved corrosion inhibiting antifreeze is available, water must be mixed with the following corrosion-protection agents to provide a coolant: S S

Product DCA 4 Diesel Coolant Additives Product Caltex XLI / Delo XLI / Texaco XLI / Havoline XLI

In this case change coolant each year.

Check the concentration in the context of maintenance work and correct as required.

NOTE! The mixing of different corrosion-inhibiting antifreeze can lead to a deterioration in the characteristics of the coolant.

S S

Do not combine different products!

Coolant containing silicate and silicate-free coolant must never be mixed, since this can lead to damage to the cooling system!

NOTE! If a changeover is made between corrosion-inhibiting antifreeze and corrosion-inhibitor or vice versa: S

Drain coolant.

Product designation

Manufacturer

Product DCA 4 Diesel Coolant Additives

Fleetguard / Cummins Filtration

Caltex XLI / Delo XLI

Caltex (Asia)

Texaco XLI / Havoline XLI

Chevron (North and South America)

Havoline XLI

Arteco (Asia and Europe)

119

Diesel Engines D856

Lubrication and Fuels, Lubricants and Coolants

120

Diesel engines D856

Listings

13Listings

121

Diesel engines D856

Listings 13.1 Abbreviations A . . . . . . . . . Amps

MAX . . . . . . Maximum

Ah . . . . . . . . Amp hours

MFR . . . . . . Engine-Guidance-Computer

bzw. . . . . . . and/or, respectively

min . . . . . . . Minutes

C . . . . . . . . . Celsius

MIN . . . . . . Minimum

cm3 . . . . . . cubic centimetres

mm . . . . . . . Millimetre

EDC . . . . . . Electronically controlled diesel injec­ tion (Electronic Diesel Control)

NC . . . . . . . Not Connected

evtl. . . . . . . if necessary/if required Fa. . . . . . . . Firm FFR . . . . . . Vehicle-Guidance-Computer ggf. . . . . . . . if necessary GND . . . . . . Ground h . . . . . . . . . Hours Chap. . . . . . Chapter kg . . . . . . . . Kilogram Tl. . . . . . . . . Terminal kW . . . . . . . Kilowatt LED . . . . . . Light Emitting Diode m . . . . . . . . Metre

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Nm . . . . . . . Newton metres TDC . . . . . . Top dead centre usw. . . . . . . etc.

BDC . . . . . . Bottom dead centre V . . . . . . . . . Volt W . . . . . . . . Watt e.g. . . . . . . . for example zul. . . . . . . . permissible > . . . . . . . . . greater than < . . . . . . . . . less than rpm . . . . . . . Revolutions per minute

Diesel engines D856

Listings 13.2 Specialist words CAN, developed by Bosch at the start of the nine­ teen eighties, was intended specially for the fast exchange of serial data between electronic control equipment in motor vehicles. With CAN each mes­ sage to be transferred is uniquely identified by a message identifier.

In contrast to station addressing, no control unit is addressed, but rather the message itself. So that basically a given message is available for receipt by every CAN Bus station. The transfer of a mes­ sage depends solely on the decision of the control unit.

It is therefore possible, that a message can be re­ ceived by one, several or by all control units for further processing.

CR, Common Rail, freely translated: Common line.

Whilst conventional diesel direct injection gene­ rates the fuel pressure anew for each injection pro­ cess, in the case of the common rail system it is built up independent of the injection sequence and remains permanently available in the fuel line.

Pressure creation and injection take place in­ dependently of each other. This technology ena­ bles the injection system to provide just the right amount of injected fuel, resulting in a favourable effect on fuel consumption and exhaust gas emissions.

EDC, Electronic Diesel Control, is an electronically controlled diesel injection. It positively influences fuel consumption, economy, exhaust and noise behaviour.

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Diesel engines D856

Listings 13.3 Key word listing B

D

Behaviour in the event of danger . . . . . . . . . . . . 22

Data on the engine type plates . . . . . . . . . . . . . . 44 Decommissioning and recommissioning . . . . . 109

C

Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Care and Maintenance . . . . . . . . . . . . . . . . . . . . . 63

Dimensions and weight . . . . . . . . . . . . . . . . . . . . 111

Change fuel filter insert . . . . . . . . . . . . . . . . . . . . . 76

Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Change Oil Filter Element . . . . . . . . . . . . . . . . . . 68

Drain fuel filter - condensation water . . . . . . . . . 75

Check coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Check cooling and heating system for sealing and condition . . . . . . . . . . . . . . . . . . . . 80

E

Check Engine Oil Level . . . . . . . . . . . . . . . . . 50, 70

Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Check fuel level and top up . . . . . . . . . . . . . . . . . 48

Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . 27

Check sensors, actuators, cable mountings and plugs for condition . . . . . . 86

Engine Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . 27

Check the batteries and cable connections . . . . 86

Engine change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Engine type plate . . . . . . . . . . . . . . . . . . . . . . . 25, 26 Engine views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Check the concentration of the corrosion inhibitor in the coolant . . . . . . . 83

Engine, general . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Check the control unit mounting for condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . 8

Check the flame start system . . . . . . . . . . . . . . . 71 Check the intake and exhaust system for condition, check sealing . . . . . . . . . . . . . . . . . 71 Check the oil pan, engine mounting and engine console for correct seating . . . . . . . 70

Exhaust gas after treatment (SCR) . . . . . . . . . . 53

F Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Fill engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . 46, 69

Check the vacuum indicator of the air filter . . . . 86

Fill with coolant . . . . . . . . . . . . . . . . . . . . . . . . 46, 82

Check the valve of the diesel engine brake . . . . 71

fill with fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Check the water separator on the fuel prefilter and drain off water . . . . . . . 78

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Fuel System, General . . . . . . . . . . . . . . . . . . . . . . 27

Check valve clearance and adjust . . . . . . . . . . . 89 Check valve control timing . . . . . . . . . . . . . . . . . . 97

G

Clean the dust discharge valve of the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Greasing the starter ring gear on the flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Cleaning fuel pre-cleaner . . . . . . . . . . . . . . . . . . . 74 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Conditions of guarantee . . . . . . . . . . . . . . . . . . . . 11 Construction and function . . . . . . . . . . . . . . . . . . 27 Content of the operating instruction . . . . . . . . . . 14 Control and Operation . . . . . . . . . . . . . . . . . . . . . 47 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . 11

124

I Information on the Operating Instruction . . . . . . . 7 Installation - Engine . . . . . . . . . . . . . . . . . . . . . . . . 44 Installation and Commissioning . . . . . . . . . . . . . . 43 Intake and Exhaust System . . . . . . . . . . . . . . . . . 27 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Diesel engines D856

Listings L

S

Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . 9

Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Lubrication and Fuels, Lubricants and Coolants . . . . . . . . . . . . . . . . . . . 114

SCR carbamide pump . . . . . . . . . . . . . . . . . . . . 101

M Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . 65 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . 67 Modifications and changes . . . . . . . . . . . . . . . . . . 14 O Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Operation monitoring system . . . . . . . . . . . . . . . . 52 Other relevant documentation . . . . . . . . . . . . . . . . 9 P Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Personal protection equipment . . . . . . . . . . . . . . 16 Personnel requirements . . . . . . . . . . . . . . . . . . . . 15 Preparation before operation . . . . . . . . . . . . . . . . 48

Signs and notices . . . . . . . . . . . . . . . . . . . . . . . . . 23 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Special dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 T Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Top up coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Top up with engine oil . . . . . . . . . . . . . . . . . . . . . . 51 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Transport inspection . . . . . . . . . . . . . . . . . . . . . . . 38 Transport, Packaging and Storage . . . . . . . . . . . 35 V Vent fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Vent the fuel prefilter . . . . . . . . . . . . . . . . . . . . . . . 78

Protection of copyright . . . . . . . . . . . . . . . . . . . . . . 9 Protection of the environment . . . . . . . . . . . . . . . 24 R Recommissioning of decommissioned engines . . . . . . . . . . . . . . . . . . 110 Replace coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Replace dry air filter safety element . . . . . . . . . . 87 Replace fuel prefilter element . . . . . . . . . . . . . . . 79 Replace Poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . 87 Replace the dry air filter main element . . . . . . . . 87 Requirements at the installation location, space requirement . . . . . . . . . . . . . . . . . . . . . . . . 111 Responsibility of the operator . . . . . . . . . . . . . . . 14

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Diesel engines D856

Notes 14

Notes

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