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Operating Instructions
Diesel Engine
D 2866 E
D 2866 TE
D 2866 LE
D 2866 LXE
Preface
Dear Customer
These Operating Instructions are intended to familiarize you with your new MAN Diesel engine and how it operates.
This manual is supplemented by the publication “Fuels, Lubricants and Coolants for MAN
Diesel Engines” and the “Service record”.
Note:
All three publications belong to the engine and must always be kept ready to hand near the engine in the engine room.
Please read this Manual and the “Instructions for the installation of MAN Diesel Engines” before you put the new engine into operation.
Comply in full with instructions relating to operation, prevention of accidents and environmental protection.
MAN Diesel engines are developed and manufactured in line with the latest state of the art. However, trouble-free operation and high performance can only be achieved if the specified maintenance intervals are observed and only approved fuels, lubricants and coolants are used.
It is imperative and in your own interest to entrust your MAN Local Service Centre with the removal of any disturbances and with the performance of checking, setting, and repair work.
Yours faithfully,
MAN Nutzfahrzeuge Aktiengesellschaft
Werk Nürnberg
Subject to change to keep abreast with technological progress.
2001 MAN Nutzfahrzeuge Aktiengesellschaft
No parts of this publication may be reproduced or translated without prior written permission of MAN. MAN explicitly reservs all rights according to copyright law.
MTDA |
Technical status: 11.1998 |
51.99493–8264 |
1
Index
Declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Engine lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Commissioning and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 During operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Shutting down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Temporary decommissioning of engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Engine lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Checking and setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 To check and set the start of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
To check and adjust valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2
Declaration
Declaration
In accordance with Article 4, paragraph 2, in conjunction with Appendix II, section B, of Directive 89/392/EEC, version 93/44/EEC
MAN Nutzfahrzeuge Aktiengesellschaft,
hereby declares that the engine described below is destined for installation in a machine as defined in the EC directive on machines.
Engine model:
Design:
Engine number:
Rating / speed:
For data see original declaration
If required this declaration is enclosed with the delivery note.
Note:
The manufacturer of the complete ready-to-use machine in which this engine is to be installed must take the further action necessary in the context of indirect safety-re- lated engineering and provision of instructions to ensure that the ready-to-use machine complies with the requirements of the EC directive on machines.
The engine must not be put into operation until the complete machine satisfies the conditions laid down in the EC directive on machines 89/392/EEC, most recently amended by 93/44/EEC, or the latest amendment of said directive.
MAN Nutzfahrzeuge Aktiengesellschaft
Vogelweiherstraße 33
D–90441 Nürnberg
3
Nameplates
MAN Nutzfahrzeuge Aktiengesellschaft
Typ
Motor-Nr. / Engine No.
NI/II
Model
......................................................................
delivered on
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installed on
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In all your correspondence please always quote engine model, serial number and job number (Order number).
Enter 14-digit serial number (is used in the spare parts catalog to distinguish between spare parts).
Enter 14-digit engine serial number.
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MAN Nutzfahrzeuge Aktiengesellschaft |
Enter 6-digit job number |
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Werk Nürnberg Germany |
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(Order number). |
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Bauj. Year |
Typ |
Model |
Motor–Nr. |
Serial No |
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Werk–Nr. |
Job No |
Leistung kW Rating kW |
Drehz. 1/min |
Speed rpm |
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Temp.°C |
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Leistg. PS Rating BHP |
Aufstellhohe m uNN Altitude m |
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–0219 |
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4
Safety regulations
General notes
Handling diesel engines and the necessary resources is no problem when the personnel commissioned with operation and maintenance are trained accordingly and use their common sense.
This summary is a compilation of the most important regulations. These are broken down into main sections which contain the information necessary for preventing injury to persons, damage to property and pollution. In addition to these regulations those dictated by the type of engine and its site are to be observed also.
Important:
If, despite all precautions, an accident occurs, in particular through contact with caustic acids, fuel penetrating the skin, scalding from hot oil, anti-freeze being splashed in the eyes etc., consult a doctor immediately.
Regulations designed to prevent accidents with injury to persons
During commissioning, starting and operation
DBefore putting the engine into operation for the first time, read the operating instructions carefully and familiarize yourself with the “critical” points. If you are unsure, ask your MAN representative.
DFor reasons of safety we recommend you attach a notice to the door of the engine room prohibiting the access of unauthorized persons and that you draw the attention of the operating personal to the fact that they are responsible for the safety of persons who enter the engine room.
DThe engine must be started and operated only by authorized personnel.
Ensure that the engine cannot be started by unauthorized persons.
DWhen the engine is running, do not get too close to the rotating parts. Wear close-fit- ting clothing.
DDo not touch the engine with bare hands when it is warm from operation – risk of burns.
DExhaust gases are toxic. Comply with the instructions for the installation of MAN Diesel engines which are to be operated in enclosed spaces. Ensure that there is adequate ventilation and air extraction.
DKeep vicinity of engine, ladders and stairways free of oil and grease. Accidents caused by slipping can have serious consequences.
5
Safety regulations
During maintenance and care
DAlways carry out maintenance work when the engine is switched off. If the engine has to be maintained while it is running, e.g. changing the elements of change-over filters, remember that there is a risk of scalding. Do not get too close to rotating parts.
DChange the oil when the engines is warm from operation.
Caution:
There is a risk of burns and scalding. Do not touch oil drain plugs or oil filters with bare hands.
DTake into account the amount of oil in the sump. Use a vessel of sufficient size to ensure that the oil will not overflow.
DOpen the coolant circuit only when the engine has cooled down. If opening while the engine is still warm is unavoidable, comply with the instructions in the chapter entitled
“Maintenance and Care”.
DNeither tighten up nor open pipes and hoses (lube oil circuit, coolant circuit and any additional hydraulic oil circuit) during the operation. The fluids which flow out can cause injury.
DFuel is inflammable. Do not smoke or use naked lights in its vicinity. The tank must be filled only when the engine is switched off.
DWhen using compressed air, e.g. for cleaning the radiator, wear goggles.
DKeep service products (anti-freeze) only in containers which can not be confused with drinks containers.
DComply with the manufacturer’s instructions when handling batteries.
Caution:
Accumulator acid is toxic and caustic. Battery gases are explosive.
When carrying out checking, setting and repair work
DChecking, setting and repair work must be carried out by authorized personnel only.
DUse only tools which are in satisfactory condition. Worn open-end wrench slip, which could lead to injury.
DWhen the engine is hanging on a crane, no-one must be allowed to stand or pass under it. Keep lifting gear in good condition.
DWhen working on parts which contain asbestos, comply with the notes at the end of this chapter.
6
Safety regulations
DWhen checking injectors do not put your hands under the jet of fuel. Do not inhale atomised fuel.
DWhen working on the electrical system disconnect the battery earth cable first.
Connect it up again last in order to prevent short circuits.
DWhen welding comply with the “Instructions for welders”.
Regulations designed to prevent damage to engine and premature wear
Do not demand more from the engine than it is able to supply in its intended application. Detailed information on this can be found in the sales literature. The injection pump must not be adjusted without prior written permission of MAN Nürnberg.
If faults occur, find the cause immediately and have it eliminated in order to prevent more serious damage.
Use only genuine MAN spare parts. MAN will accept no responsibility for damage resulting from the installation of other parts which are supposedly “just as good”.
In addition to the above, note the following points:
DNever let the engine run when dry, i.e. without lube oil or coolant.
DWhen starting do not use any additional starting aids (e.g. injection with starting pilot).
DUse only MAN-approved service products (fuel, engine oil, anti-freeze and anti-cor- rosion agent). Pay attention to cleanliness. The Diesel fuel must be free of water. See “Maintenance and care”.
DHave the engine maintained at the specified intervals.
DDo not switch off the engine immediately when it is warm, but let it run without load for about 5 minutes so that temperature equalization can take place.
DNever put cold coolant into an overheated engine. See “Maintenance and care”.
DDo not add so much engine oil that the oil level rises above the max. marking on the dipstick. Do not exceed the maximum permissible tilt of the engine.
Serious damage to the engine may result if these instructions are not adhered to.
DAlways ensure that the testing and monitoring equipment (for battery charge, oil pressure, coolant temperature) function satisfactorily.
7
Safety regulations
DComply with instructions for operation of the alternator. See “Commissioning and operation”.
DDo not let the raw water pump run dry. If there is a risk of frost, drain the pump when the engine is switched off.
Regulations designed to prevent pollution
Engine oil and filter elements / cartridges, fuel/fuel filter
DTake old oil only to an old oil collection point.
DTake strict precautions to ensure that no oil or Diesel fuel gets into the drains or the ground.
The drinking water supply could be contaminated.
DFilter elements are classed as dangerous waste and must be treated as such.
Coolant
DTreat undiluted anti-corrosion agent and / or antifreeze as dangerous waste.
DWhen disposing of spent coolant comply with the regulations of the relevant local authorities.
Notes on safety in handling used engine oil
Prolonged or repeated contact between the skin and any kind of engine oil decreases the skin. Drying, irritation or inflammation of the skin may therefore occur. Used engine oil also contains dangerous substances which have caused skin cancer in animal experiments. If the basic rules of hygiene and health and safety at work are observed, health risks are not to the expected as a result of handling used engine oil.
Health precautions:
DAvoid prolonged or repeated skin contact with used engine oil.
DProtect your skin by means of suitable agents (creams etc.) or wear protective gloves.
DClean skin which has been in contact with engine oil.
–Wash thoroughly with soap and water. A nailbrush is an effective aid.
–Certain products make it easier to clean your hands.
–Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.
8
Safety regulations
DAfter washing apply a fatty skin cream to the skin.
DChange oil-soaked clothing and shoes.
DDo not put oily rags into your pockets.
Ensure that used engine oil is disposed of properly
– Engine oil can endanger the water supply –
For this reason do not let engine oil get into the ground, waterways, the drains or the sewers. Violations are punishable.
Collect and dispose of used engine oil carefully. For information on collection points please contact the seller, the supplier or the local authorities.
Adapted from “Notes on handling used engine oil”.
Note on parts containing asbestos
DCertain parts of the engine (gaskets) may contain asbestos. Spare parts and, where necessary, their packaging is marked accordingly (see illustration below).
DWhen parts that contain asbestos are machined fine asbestos dust may be released. To prevent possible damage to health please take appropriate safety precautions and follow the advice given below:
DWherever possible work in the open air or in well ventilated rooms.
DIf possible use hand-operated or slow-running machines, if necessary with a dust trap. If fast-running machines are used they ought always to have such a device.
DWet the material before cutting or drilling it.
ACHTUNG ATENÇÃO |
VAROITUS VOORZICHTIG |
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ENTHÄLT |
CONTEM |
SISÄLTÄÄ |
BEVAT |
ASBEST |
AMIANTO |
ASBESTIA |
ASBEST |
Gesundheits- |
Respirrar po de |
Asbestipölyn |
Het inademen van |
gefährdung bei amianto é perîgroso hengittäminen on |
asbeststof |
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Einatmen von |
para a saúde |
terveydelie |
is schadelijk voor |
Asbeststaub |
Consulte as normas |
vaarallistta |
de gezondheit |
Sicherheits- |
de segurança |
Noudattakaa |
Houdt u aan de |
vorschriften |
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turvaohjeita |
veiligheids- |
beachten |
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voorschriften |
ATTENTION |
ARTIKELN |
ATTENZIONE |
CONTIENT DE |
INNEHÅLLER |
CONTIENE |
L’AMIANTE |
ASBEST |
AMIANTO |
Respirer la |
Dammet är |
Resirare polvere di |
poussière d’amiante |
farligt vid inandning |
amiento é |
est dangereux |
Innehåller |
pericoloso |
pour la santé |
Asbest |
per la salute |
Suicre les consignes |
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Seguire le norme |
de sécurite |
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di sicurezza |
INNEHOLDER |
WARNING |
PRECAUCIÓN |
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ASBEST |
CONTAINS |
:CONTIENE |
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Innånding av stov |
ASBESTOS |
AMIANTO |
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fra dette materialet |
Breathing asbestos |
Evitese ta |
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kan forårske kreft |
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dust is dangerous |
generación |
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Langvarig eller gjentatt |
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to health Follow |
de polvo |
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påvirkning øker risikoen |
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safety Instructions |
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Bruk egnet vemeutstyr |
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DWet the dust, put it into a tightly closing container and have it disposed of as dangerous waste.
9
Technical information
Engine views D 2866 E
1 |
2 |
3 |
4 |
5 |
9 |
8 |
7 |
6 |
13 |
12 |
11 |
10 |
10
Technical information
1Tensioning pulley
2Water pump
3Oil filler neck
4Tandem fuel filter
5Oil separator valve for crankcase breather
6Fuel lift pump with prestrainer
7Injection pump
8Oil drain plug
9Oil dipstick
10Alternator
11Oil cooler
12Oil filter
13Starter motor
11
Technical information
Engine views D 2866 TE
13 |
12 |
11 |
10 |
12
Technical information
1Tensioning pulley
2Water pump
3Oil filler neck
4Oil separator valve for crankcase breather
5Tandem fuel filter
6Fuel lift pump with prestrainer
7Injection pump
8Oil drain plug
9Oil dipstick
10Oil cooler
11Oil filter
12Turbocharger
13Starter motor
13
Technical information
Engine views D 2866 LE, LXE
1 |
2 |
3 |
7 |
6 |
5 |
4 |
8
14 |
13 |
12 |
11 |
10 |
9 |
14
Technical information
1Oil filler neck
2Oil separator valve for crankcase breather
3Tandem fuel filter
4Fuel lift pump with prestrainer
5Injection pump
6Oil dipstick
7Alternator
8Water pump
9Tensioning pulley
10Oil filter
11Water drain plug
12Oil drain plug
13Turbocharger
14Starter motor
15
Technical information
Engines
The engines D 2866 E / TE / LE / LXE are in-line vertical liquid-cooled 6-cylinder fourstroke Diesel engines with direct injection. D 2866 E is a naturally aspirated engine. D 2866 TE is turbocharged, and D 2866 LE / LXE are turbocharged and intercooled.
Engine block
The cylinder block is a single piece of alloy cast iron. To increase its stiffness, it is extended to a level below the crankshaft centre line. The engine has replaceable wet cylinder liners and individual cylinder heads with shrunk-in valve seat rings and replaceable valve guides.
Piston / Conrod / Crank assembly
The forged crankshaft has screwed-on counterweights. Radial seals with replaceable wearing rings on crankshaft and flywheel are provided to seal the crankcase penetrations.
The connecting rods are die-forged, diagonally split and can be removed through the top of the cylinders together with the pistons. Crankshaft and connecting rods run in steelbacked lead bronze ready-to-fit type bearings.
16
Technical information
Engine timing
Camshaft, oil pump and injection pump are driven by a gear train arranged at the flywheel end.
5
6 
4
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1 |
2 |
3 |
1 |
Crankshaft gear |
4 |
Camshaft drive gear |
2 |
Oil pump drive gear |
5 |
Idler gear |
3 |
Oil pump impeller gears |
6 |
Injection pump drive gear |
The crankshaft gear and camshaft gear are match-marked by “1” or “D”.
Valves
The overhead valves are actuated via chilled cast iron tappets, push rods and rocker arms from the camshaft.
17
Technical information
Engine lubrication
The engine is equipped with force-feed lubrication.
The pressure is produced by a gear pump whose drive gear is in direct mesh with the crankshaft gear at the flywheel end.
The oil pump draws the oil from the oil sump and delivers it through the oil cooler and oil filter to the main distributor gallery and from there to the main bearings, big-end bearings and camshaft bearings as well as to the small-end bearings and the rocker arms.
8
7
6
9
10
5
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1 |
2 |
3 |
4 |
1 |
Oil suction pipe |
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7 |
Oil filter |
2 |
Main oil galleries |
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8 |
Turbocharger |
3 |
Jets for piston cooling and cam lubrication |
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(D 2866 TE / LE / LXE only) |
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4 |
Oil pump |
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9 |
Oil cooler |
5 |
Oil relief valve |
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10 |
Injection pump |
6 |
Bypass valve |
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18
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