Man D 2866 LE 401, D 2866 LE 402, D 2866 LE 403, D 2876 LE 403, D 2866 LE 405 Repair Manual
...
Preface
This Repair Manual is designed to facilitate competent repair of the engines listed herein.
The pictures and relevant descriptions show typical work that may not always be applicable to the engine in
hand, which nevertheless does not mean that they are not correct. In such cases the repair work is to be
planned and carried out in a similar way.
The expert knowledge necessary for handling Diesel engines was taken for granted when this publication
was compiled.
Any repair of components such as injection pump, alternator etc. ought to be left to our or the manufacturer’s service department.
MAN Nutzfahrzeuge Aktiengesellschaft
Nuremberg Works
We reserve the right to make technical modifications in the course of further development.
1999 MAN Nutzfahrzeuge Aktiengesellschaft
Reprinting, copying or translation, even in the form of excerpts, is forbidden without the written permission
of MAN. MAN expressly reserves all rights in accordance with the law on copyright.
MTDA / 05.99 51.99493-8428
1
Contents
Safety instructions 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General information on the overhaul of engines 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trouble shooting table 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine views, D 2866 LE401 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Schematic diagram of engine lubrication system 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Schematic diagram of fuel system 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Schematic diagram of cooling system 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel system
Checking and adjusting start of fuel delivery 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing injection pump 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fuel injectors 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking and repairing fuel injectors 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning fuel prefilter 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing fuel filter cartridges 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling system
Draining and filling with coolant 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing thermostat 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing water pump 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repairing water pump 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repairing water pump 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and attaching expansion tank 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing heat exchanger 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning heat exchanger pipe set 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Raw water pump 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
Lubrication
Changing oil filter 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing oil cooler 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing oil pump 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil spray nozzle 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel / Crankshaft seal
Removing and installing vibration damper, changing front crankshaft seal 58 . . . . . . .
Removing and installing flywheel, replacing gear ring 62 . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing crankshaft seal (flywheel end) 64 . . . . . . . . . . . . . . . . . . . . . . .
Exchanging bearing race 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft seals 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake / exhaust system
Removing and installing intake manifold 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbocharger, trouble shooting 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the charge-air pressure 72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing turbocharger 73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking axial and radial play of turbocharger rotor shaft 75 . . . . . . . . . . . . . . . . . . . . .
Exchanging waste gate 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing intercooler 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
Contents
Cylinder head
Removing and installing cylinder head 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting valve clearance 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembling and assembling rocker arms 86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing valves 87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing valve guides 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing valve seat insert 91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reworking valve seat 93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refacing valves 96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking compression 97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve timing
Removing and installing timing case 98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing camshaft, exchanging camshaft bearing 99 . . . . . . . . . . . . . .
Checking valve timing 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankgear, pistons
Removing and installing crankshaft 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing piston with connecting rod 105. . . . . . . . . . . . . . . . . . . . . . . . . . .
Detaching piston from and attaching to connecting rod
checking - changing connecting rod 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing, installing and changing piston rings 110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing cylinder liners 112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring piston protrusion 115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing starter 116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V-belts 117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant level probe 119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Attachments
Special tools 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 135. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Safety instructions
General information
This brief overview summarises important instructions and is structured into areas of main concern in order
to impart the knowledge necessary to prevent accidents involving injury to persons, damage to the engine
or other property and harm to the environment. Additional notes are included in the operator’s manual for
the engine.
Important: If despite all safety precautions an accident occurs as a result of contact with caustic acids,
penetration of fuel into the skin, scalding with hot oil, anti-freeze splashes into the eyes etc, consult a doc-
tor immediately!
1. Instructions for preventing accidents with injury to persons
Checks, setting jobs and repair work must be carried out by authorised skilled personnel only.
D When carrying out maintenance and repair work, ensure that the engine cannot be ac-
cidentally started from the bridge by unauthorised persons.
D The engine must be started and operated by authorised personnel only.
D When the engine is running, do not get too close to revolving components. Wear tight-
fitting working clothes.
D Do not touch hot engine with bare hands: risk of burning yourself.
D Keep engine vicinity, ladder and steps free of oil and grease. Accidents resulting from
slipping may have serious consequences.
D Work only with tools that are in good condition. Worn spanners slip: risk of injuries.
D Persons must not stand under an engine suspended from a crane hook. Keep lifting
gear in good order.
D Open coolant circuit only after the engine has cooled down. If opening the coolant cir-
cuit while the engine is hot is unavoidable, observe the instructions in the chapter
”Maintenance and care” in the Operator’s Manual.
D Neither retighten nor open pressurised pipelines and hoses (lube oil circuit, coolant cir-
cuit and downstream hydraulic oil circuit if fitted): risk of injuries resulting from emerging
fluids.
4
Safety instructions
D When checking the injection nozzles, do not hold your hands in the fuel jet. Do not in-
hale fuel mist.
D When working on the electrical system, unplug earth cable from battery first and recon-
nect it last to avoid short-circuits.
D Observe the manufacturer ’s instructions for handling batteries.
Caution:
Battery acid is toxic and caustic. Battery gases are explosive.
D When carrying out welding work, observe the ”Information sheets for welders”.
5
Safety instructions
2. Instructions for preventing damage to the engine and premature wear
D Prior to repairing the engine, clean it thoroughly. Ensure that dirt, sand or foreign matter will
not get into the engine during repair work.
D In the event of operational faults immediately identy the cause and rectify to prevent more serious dam-
age.
D Always use genuine MAN parts only. Installation of ”equally” good parts from other suppliers may cause
severe damage for which the workshop carrying out the work is responsible.
D Never operate the engine while it is dry, i.e. without lubricant or coolant.
Use a suitable label to mark engines not ready for operation.
D Only use operating materials (fuel, engine oil, antifreeze and anticorrosion agents) approved by MAN.
Ensure that everything is kept clean. Diesel fuel must be free of water.
D Do not fill up with engine oil above the max. notch on the dipstick. Do not exceed the engine’s
maximum permissible operating inclination.
Non–compliance with these instructions may cause severe engine damage.
D Control and monitoring devices (charge check, oil pressure, coolant temperature) must work faultlessly.
D Observe the instructions for operating the alternator; see chapter ”Commissioning and operation” in the
Operator’s Manual.
3. Instructions for preventing environmental damage
Engine oil and filter cartridges and elements, fuel/fuel filters
D Take old oil to an old oil disposal point only.
D Ensure without fail that oil and Diesel fuel will not get into the sewerage system or the ground.
Caution:
Danger of contaminating potable water!
D Treat filter elements and cartridges as special waste.
Coolant
D Treat undiluted anticorrosion and/or antifreeze agents as special waste.
D The regulations of the relevant local authorities are to be observed for the disposal of spent coolants.
6
Safety instructions
4. Instructions for handling used engine oil *
Prolonged or repeated contact of any kind of engine oil with the skin causes the skin to degrease, which
may result in dryness, irritation or inflammation. Old engine oil also contains hazardous substances which
in animal experiments have caused skin cancer. Handling old engine oil does not pose any health hazard if
the basic safety and hygiene related regulations are observed.
Health and safety regulations:
D Avoid prolonged, excessive or repeated contact of old engine oil with the skin.
D Use a suitable skin protection agent or wear protective gloves.
D Clean the skin that has been in contact with engine oil.
– Wash yourself thoroughly with soap and water. A nailbrush is an effective aid.
– Special hand cleaning agents facilitate cleaning soiled hands.
– Do not use petrol, Diesel fuel, gas oil, fluxes or solvents as cleaning agents.
D After washing apply moisturising handcream to your skin.
D Change oil-soaked clothes and shoes.
D Do not put any oil-soaked cloths into pockets.
Pay meticulous attention to the proper disposal of old engine oil.
– Old oil is a water hazard –
Therefore, do not pour any old oil into the ground, the drains or the sewerage system. Any violation of this
rule is punishable.
Collect and dispose of old engine oil properly. For information concerning collection points, contact seller,
supplier or the local authorities.
∗ Based on the ”Merkblatt für den Umgang mit gebrauchtem Motorenöl”
(Notes on how to handle old engine oil).
7
General information on the overhaul of engines
Very different factors have an influence on the life expectancy of an engine. For this reason it is not possible to give certain predetermined numbers of operating hours for basic overhauls.
Regular interim inspections and overhauls frequently carried out on large engines (e.g. on those from MAN
Augsburg) are generally not necessary on MAN Diesel engines from the MAN Nuremberg works.
In our opinion, opening an engine or carrying out a basic overhaul is not appropriate as long as the engine
achieves good compression values and the following operating values measured and recorded and have
not changed significantly since commissioning:
D Charge-air pressure
D Exhaust-gas temperature
D Coolant and lube-oil temperature
D Oil pressure and oil consumption
D Formation of smoke
The following criteria have a major influence on the life expectancy of an engine:
D Correct output setting according to the type of operation.
D Expert installation in accordance with the installation instructions.
D Inspection of the installation by authorized personnel.
D Regular maintenance as per maintenance plan
D Selection and quality of lube oil, fuel and coolant as specified in the publication
”Fuels, Lubricants, Coolants for Industrial and Marine Diesel Engines”.
8
Trouble shooting table
Faults and possible causes
We recommend
Repair work is to be considered complete only after the damage which has occurred and the possible
causes have been eliminated. Ascertaining the causes of damage is frequently more difficult than eliminating the damage caused. For this reason we recommend you have the operational fault exactly described to
you before removal or disassembly work is commenced. Then, track down the probable causes by asking
specific questions, examining and eliminating these causes one by one with the aid of the table and your
own experience. This helps to reduce repairs to those necessary and counter complaints about ”premature” exchange of parts and expensive working and downtimes.
Remark:
The subsequent list is meant to be a memory aid so that no causes of damage will be overlooked in the
elimination of faults. The precondition for this, however, is that you are familiar with the Repair Manual for
the engine and the relevant Operating Instructions as well as the publication ”Fuels, Lubricants, Coolants
for Industrial and Marine Diesel Engines”.
9
Trouble shooting table
Fault Probable cause
Starter does not crank
the engine or only too
slowly
Engine does not start D Fuel tank empty
Engine does not start
while cold
Engine does not run
smoothly, and stops
D Battery main switch in ”off” position
D Batteries flat
D Crankgear blocks
D Battery cable connections loose or cor-
roded
D Starter electromagnetic switch sticking
(clicks)
D Cable connection from ignition lock to
starter electromagnetic switch is loose
or interrupted
D Starter electromagnetic switch faulty
D Starter defective (carbon brushes loose,
winding faulty, short-circuit to earth)
D Engine oil viscosity not suitable
D Starter interlock relay defective
D Fuel valve shut
D Cut-off solenoid in “STOP” position
D Air in fuel system
D Fuel lines leaky, ruptured, clogged
D Fuel filter / prefilter clogged
D Suction height of fuel delivery pump
(max. 1m) exceeded
D Fuel delivery pump faulty
D Air supply/exhaust gas pipes clogged
D Unsuitable fuel
D Delivery start incorrect
D Valve clearance incorrect
D Injection nozzles worn
D Compression insufficient
D Fuel filter clogged with paraffin
D Engine oil viscosity unsuitable
see: ”Engine does not start”
D Lower idle speed set too low
D Air in fuel system
D Fuel lines leaky, ruptured, clogged
D Fuel filter clogged
D Inlet chamber pressure of injection
pump too low
D Fuel high-pressure part leaky
D Injector needle sticking
D Delivery start set incorrectly
D Injection pump set incorrectly or
defective
D Valve clearance incorrect
D Compression insufficient
Remedy
(This column is filled in only if the
”probable cause” gives no clue as
to what must be done).
D Knock on the magnet
D Check with check lamp
D See ”Fuels, Lubricants ...”
D Checking: Connect terminals
50e and 50f
D See ”Fuels, Lubricants ...”
D Remedy by Bosch Service
10
Trouble shooting table
Fault
Engine speed variations
during operation
Engine cannot be
stopped
Performance unsatisfactory, max. boat
speed is not reached
Probable cause
D Too little fuel in fuel tank
D Air in fuel system
D Fuel lines leaky
D Fuel high-pressure part leaky
D Injection nozzles defective, worn
D Speed governor defective D Remedy by Bosch Service
D Cut-off linkage bent or jammed
D Cut-off solenoid without voltage
D Injection pump set incorrectly or
defective
D Engine speed adjusting lever not in
full-load position
D Incrustation of hull, shaft system and
propeller with foreign matter
D Propeller consumes too much power,
nominal speed is not reached
D Propeller consumes too much power,
engine runs in the breakaway range
D Flow of water on to the propeller insuffi-
cient
D Fuel temperature too high
D Unsuitable, contaminated fuel
D Fuel filter clogged
D Air in fuel system
D Lack of fuel
D Temperature in engine room too high,
combustion air and fuel too hot
D Supply of combustion air insufficient,
intake vacuum too high
D Charge-air pipes leaky
D Intercooler contaminated
D Turbocharger contaminated or defective
D Compression insufficient
D Injection pump and / or governor
defective
Remedy
(This column is filled in only if the
”probable cause” gives no clue as
to what must be done).
D Remedy by Bosch Service
D Route the ship-mounted fuel
lines well apart from the hot engine parts.
D See ”Fuels, Lubricants ...”
D Check fuel lines and delivery
pump
D Check inward and outward ven-
tilation
D Check intake air supply to air
filters
D Remedy by Bosch Service
11
Trouble shooting table
Fault
Coolant temperature
too high, coolant loss
Probable cause
D Coolant level too low
D Air in coolant circuit
D Proportion of anti-freeze / anticorrosion
agent too high
D Raw water supply clogged
D Raw water supply insufficient
D Cap with working valves on expansion
tank defective, leaky
D Thermostat in closed position blocked
D Heat exchanger heavily contaminated,
pipe group coated with foreign matter
D V-belt for water pump drive not correctly
tensioned (slipping)
D Water pump leaky, defective (bearing
damage)
D Coolant circuit clogged by foreign matter
D Thermostat jammed in ”shut” position
Remedy
(This column is filled in only if the
”probable cause” gives no clue as
to what must be done).
D See ”Fuels, Lubricants ...”
D Check inlet orifice
D Impeller worn. Measure delivery
of raw water pump and vacuum
at inlet
Lube oil pressure
varies/too low
Lub oil pressure too
high
Lube oil consumption
too high
D Oil level in oil pan too low
D Oil level in oil pan too high
D Max. inclination exceeded
D Engine temperature too high
D Oil viscosity unsuitable (viscosity too
low)
D Oil in oil pan too thin (mixed with con-
densation or fuel)
D Heavy bearing wear
D Oil pump gears heavily worn
D Safety valve in oil circuit defective (does
not shut, spring fatigued or broken)
D Oil pressure gauge defective
D Engine cold
D Oil viscosity unsuitable (viscosity too
high)
D Safety valve in oil circuit defective (does
not open)
D Oil pipes/oil galleries clogged
D Oil pressure gauge defective
D Leaks in the lube oil circuit, particularly
at the turbocharger and oil cooler
D Oil level in oil pan too high
D Lube oil quality does not satisfy regula-
tions
D Turbocharger wear
D Piston rings heavily worn
D Valve guides heavily worn
D Dipstick marked correctly?
See Operator’s Manual
D See ”Fuels, Lubricants ...”
D See ”Fuels, Lubricants ...”
D See ”Fuels, Lubricants ...”
D Measure play of rotor
12
Trouble shooting table
Fault
Fuel consumption too
high
Black smoke D Lack of combustion air, intake vacuum
Blue smoke D Engine coolant/intake air still too cold
White smoke D Engine coolant/intake air still too cold
Probable cause
D Constant full-load operation
D Speed resistance owing to incrustation
of hull, shaft system and propeller with
foreign matter
D Poor efficiency of the drive system
D Fuel quality does not satisfy regulations
D Fuel leaks in the system
D High power requirements by additional
units (hydraulic pumps, compressors
etc)
D Delivery start set incorrectly
D Injection pump set incorrectly or defec-
tive
D Valve clearance incorrect
D Intake vacuum / exhaust backpressure
too high
D Injection nozzles worn
too high
D Engine speed reduction owing to the
propeller’s taking up too much power
D Sudden full load after long low load or
idling periods
D Air filter contaminated
D Leaks in air pipes downst r eam of com-
pressor
D Diaphragm in wastegate leaky
D Intercooler leaky, defective
D Unsuitable fuel
D Turbocharger defect iv e
D Delivery start set incorrectly
D Injection nozzles defective, coked
D Injection pump set incorrectly or
defective
D Exhaust backpressure too high
D Mainly low-load operation
D Piston rings worn or broken
D Valve guides worn
D Crankcase breather clogged (overpres-
sure in crankcase)
D Water evaporates in exhaust gas pipe
during raw water injection
D Delivery start set incorrectly
D Cylinder head gasket leaky/burned
through
D Fuel quality does not satisfy regulations
D Injection nozzles defective
D Injection pump set incorrectly or
defective
Remedy
(This column is filled in only if the
”probable cause” gives no clue as
to what must be done).
D Adjust propeller
D See ”Fuels, Lubricants ...”
D Remedy by Bosch Service
D Check intake air supply to air fil-
ters (engine room ventilation)
D See ”Fuels, Lubricants ...”
D Remedy by Bosch Service
D See ”Fuels, Lubricants ...”
D Remedy by Bosch Service
13
Trouble shooting table
Fault
Vibrations, droning
noise, structure-borne
sound
Engine knocks D Engine in cold running phase
Engine is too loud D Intake or exhaust gas pipe leaky
Probable cause
D Drive system not or inaccurately aligned
D Unsuitable clutch
D Unsuitable engine/gearbox mounts
D Elastic mounts unequally loaded (height
adjustment)
D Propeller shaft unbalanced
D Delivery start set incorrectly
D Injector needle sticking
D High load at low speed
D Fuel is slow to ignite
D Compression too low
D Valve clearance too large
D V-belt slipping
D Timing gears worn, backlash of teeth
too large
Remedy
(This column is filled in only if the
”probable cause” gives no clue as
to what must be done).
14
Trouble shooting table
Fault
Starter
D Pinion does not turn
or turns too slowly
D Pinion does not
engage
D Pinion engages but
stops
D Pinion continues to
run after starter
switch has been
released
Probable cause
D Battery insufficiently charged
D Terminals loose or oxidised, poor earth
connection
D Terminals or carbon brushes have short-
circuit to earth
D Carbon brushes are stuck or have poor
contact
D Pinion or starter gear ring heavily con-
taminated or damaged
D Electromagnetic switch defective
D One-way clutch slips
D Starter switch defective
D Electromagnetic switch defective
Remedy
(This column is filled in only if the
”probable cause” gives no clue as
to what must be done).
D Pinion does not
disengage after
successful start
Alternator
D Alternator check
lamp does not come
on when engine is
stationary and starter
switch is switched on
D Alternator check
lamp brightly iluminated when engine is
running
D Alternator check
lamp brightly iluminated when engine is
stationary, dimmer or
glowing when engine
is running
D Battery does not
charge up
D Starter defective
D Check lamp burnt out
D Battery discharged
D Terminal clamps loose or oxidised
D Regulator defective
D Short-circuit in alternator
D Carbon brushes worn
D Cable D+ has short-circuit to earth
D Regulator defective
D Rectifier damaged, slip rings dirty
D V-belt slipping or cracked
D Resistance in cable between alternator
and battery is too high, terminal clamps
oxidised
D Regulator defective
D Alternator defective
D Cable between alternator and battery
interrupted
D Battery defective
D Alternator defective
D V-belt slipping
D Switch off engine immediately
D Change regulator
D Repair in specialist workshop
D Change regulator
D Repair in specialist workshop
D Change regulator
D Repair in specialist workshop
D Repair in specialist workshop
15
Engine views, D 2866 LE401
16
Engine views, D 2866 LE401
17
Cross section of engine
18
Longitudinal section
19
Schematic diagram of engine lubrication system
8
7
6
9
10
2033
1 Oil suction pipe 6 Bypass valve
2 Distributor pipe 7 Oil filter
3 Oil spray nozzle 8 Turbocharger
4 Oil pump 9 Oil cooler
5 Oil pressure relief valve 10 Injection pump
1
234
5
20
Schematic diagram of fuel system
1 Fuel tank 6 Fuel injection pump
2 Fuel prefilter 7 Overflow valve
3 Fuel delivery pump 8 Fuel injector
4 Fuel filter 9 Suction pipe
5 Bleed screw 10 Return pipe
21
Schematic diagram of cooling system
16
9
10 111514 13
1234576 8
12
2583
1 Water pump housing with 9 Expansion tank
integrated thermostat housing 10 Over/underpressure valve
2 Water pump impeller 11 Coolant filler neck
3 Engine oil cooler 12 Heating lead and return line
4 Crankcase 13 Measuring point for cooling water temperature
5 Exhaust manifold, liquid-cooled 14 Bleed screw on turbocharger
6 Turbocharger, liquid-cooled 15 Raw water pump
7 Thermostat 16 Intercooler
8 Engine coolant/raw water heat exchanger
22
Checking and adjusting start of fuel delivery
Checking start of delivery
Fig. 1
For the purpose of checking the start-of-delivery
setting, an ”OT” (= TDC) mark and a scale (2) from
10 ... 50_ before TDC are engraved on a disc fitted
in front of the torsional vibration damper. The scale
marks are read against a pointer (1) fitted to the
crankcase.
Fig. 2
To turn the engine over manually during the setting
work, a plate with a central hexagon bolt is located
on the front side of the crankshaft pulley.
1
2
1
2590
Figs. 3 and 4
There is another scale engraved on the flywheel
which can be read through an inspection hole in
the flywheel housing but access may be difficult.
The scale should be used for readjusting the
pointer after the vibration damper has been removed or replaced.
Before the vibration damper with the scale disc is
installed, the engine should be positioned at ”OT”
(= TDC) by means of the scale on the flywheel.
The pointer should then be aligned such that its
measuring edge exactly coincides with the ”OT”
mark on the scale disc.
2
3
3390
2591
23
4
2452
Checking and adjusting start of fuel delivery
Fig. 5
Remove screw plug (1) on governor housing.
If fitted, take out blocking pin (2).
If the pointer is exactly in the centre of the
inspection hole, the pump plunger for cylinder no.
1 is at start of delivery. However, it is possible to
determine exactly whether or not the pump is at
start of delivery only by means of the following
special tools:
12
a. Light signal transmitter
Fig. 6
Push light signal transmitter into socket in gover-
nor housing. Ensure that the lug (3) fits in the
groove (4). Tighten the knurled nut (5) by hand.
Connect up power supply of light signal transmitter
(red terminal = +). Turn engine by hand so that
piston in cylinder no. 1 in the compression stroke
comes close to the start of delivery.
Lamp (A) comes on shortly before start of delivery
is reached.
Fig. 7
Slowly turn the engine further until lamp (B) comes
on too. The injection pump is now at start of
delivery.
The light signal transmitter KDEP 1600 (Fig.) is
connected to the starter battery for the power supply.
5
6
2310
4
3
5
6
2309
Note:
If only lamp (B) comes on during this test,
the engine has been turned past the start of
delivery. In this case turn the engine back
and repeat the procedure.
24
7
2308
Checking and adjusting start of fuel delivery
Fig. 8
The light signal transmitter KDEP 1601 (Fig.) is
energized by its own power supply.
8
3393
b. Sleeve
Fig. 9
If a light signal transmitter is not available, good
measurement results can also be achieved with a
plug-in sleeve.
The sleeve is to be made of aluminium or steel
Set engine to start of delivery as described above.
Insert the sleeve into the governor housing up to
the stop.
The start of delivery is set exactly when the pointer
for start of delivery is in the centre of the 3 mm
bore in the sleeve.
9
2259
29
ø15
ø12
ø9
13
30
15
ø3
ø11
25
Checking and adjusting start of fuel delivery
Adjusting start of delivery
If the check according to method a) or b) should
prove that the delivery start is not correct, proceed
as follows:
Fig. 10
Remove timing case cover (13mm).
Fig. 11
Loosen all bolts fastening the drive gear to the in-
jection pump hub (13mm). For this, two complete
turns of the engine are necessary.
10
3394
Fig. 12
Turn engine to specified angle for delivery start.
Remove cylinder head cover from cylinder no. 6
(flywheel end). When the values of this cylinder
are in crossover, the piston in cylinder no. 1 is at
ignition TDC.
Remove screw plug from governor housing (see
Fig. 5). The delivery start pointer must be visible in
the centre of the inspection hole.
Turn the injection pump camshaft on the drive
flange to the left or right until the conditions mentioned under a) or b) apply.
Tighten bolts for fastening drive gear to drive
flange consecutively to 5 Nm and then to 30 Nm.
Check delivery start once again.
Close governor housing.
11
12
2325
3395
26
Removing and installing injection pump
Removing injection pump
Fig. 1
Close cut–off valve from fuel tank to engine.
Remove all fuel and air (LDA) connections from
the injection pump and detach the injection lines.
Caution:
The lines contain fuel.
Catch emerging fuel in a container.
Fig. 2
Remove bracket from the injection pump (19 mm).
1
3396
Fig. 3
Remove the mounting bolts from the injection
pump flange (17 mm).
Note:
For reasons of space the mounting bolt between the injection pump and the crankcase
(hexagon M10 bolt with reduced head 13
mm) can be reached only with a 3/8” socket
and an extension.
Fig. 4
Take off injection pump.
Note:
Ensure meticulous cleanliness when working
on the injection pump.
Prevent dirt and foreign matter from penetrating into opened line connections.
2
3
3397
3398
27
4
3399
Removing and installing injection pump
Installing injection pump
Fig. 5
Important:
If the injection pump is blocked the camshaft
must on no account be loaded or turned because parts of the blocking pin may break off
and fall into the governor. Non-compliance
with this may result in severe damage to
the injection pump.
Remove screw plug (1) from governor housing.
Take out blocking pin (2) if fitted.
Fig. 6
Turn engine to angle for delivery start.
Take cylinder head cover off cylinder no. 6 (flywheel end). When the cylinders are in crossover,
the piston of cylinder no. 1 is at TDC at the end of
the compression stroke.
12
2310
5
Fig. 7
Check whether the injection pump is in delivery
start position. To do this, remove the screw plug
from the governor housing (see Fig. 5). The delivery start pointer must be visible in the centre of the
inspection hole.
Remove the mounting bolts from the injection
pump drive gear (13 mm) so that it can be turned
in the slots.
Hold injection pump camshaft in place while turning the gear (41 mm).
Fit new O-ring (slightly coated with oil) to injection
pump flange.
6
7
3390
3400
28
Removing and installing injection pump
Fig. 8
Insert the injection pump and tighten the mounting
bolts.
Fig. 9
Apply an initial torque of 5 Nm to all mounting bolts
on the gear through the inspection hole. Two complete engine turns are necessary for this operation.
Now tighten all mounting bolts to 30 Nm.
Check delivery start, if necessary readjusting it
(see page 23).
Screw in screw plug on the governor housing and
fit cover to timing case.
8
3401
9
3395
29
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