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Man D 2866 E, Operating Instructions Manual, Page: 1 / 64

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Operating Instructions

Diesel Engine

D 2866 E
D 2866 TE
D 2866 LE
D 2866 LXE

Summary of Contents for D 2866 E

Page 1: ...Operating Instructions Diesel Engine D 2866 E D 2866 TE D 2866 LE D 2866 LXE...

Page 2: ......

Page 3: ...iesel 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 ar...

Page 4: ...issioning 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 sys...

Page 5: ...number Rating speed 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...

Page 6: ...nguish between spare parts Enter 14 digit engine serial number Enter 6 digit job number Order number MAN Nutzfahrzeuge Aktiengesellschaft Typ Motor Nr Engine No NI II Temp C Werk N rnberg Germany MAN...

Page 7: ...ation for the first time read the operating instruc tions carefully and familiarize yourself with the critical points If you are unsure ask your MAN representative D For reasons of safety we recommend...

Page 8: ...ircuit coolant circuit and any additional hydraulic oil circuit during the operation The fluids which flow out can cause injury D Fuel is inflammable Do not smoke or use naked lights in its vicinity T...

Page 9: ...pposedly just as good In addition to the above note the following points D Never let the engine run when dry i e without lube oil or coolant D When starting do not use any additional starting aids e g...

Page 10: ...th the regulations of the relevant local auth orities 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 ir...

Page 11: ...a dust trap If fast running machines are used they ought always to have such a device D Wet the material before cutting or drilling it D Wet the dust put it into a tightly closing container and have i...

Page 12: ...Technical information 10 Engine views D 2866 E 1 2 3 4 5 7 6 8 9 10 11 12 13...

Page 13: ...ey 2 Water pump 3 Oil filler neck 4 Tandem fuel filter 5 Oil separator valve for crankcase breather 6 Fuel lift pump with prestrainer 7 Injection pump 8 Oil drain plug 9 Oil dipstick 10 Alternator 11...

Page 14: ...Technical information 12 Engine views D 2866 TE 6 7 8 9 1 2 4 5 3 10 11 12 13...

Page 15: ...y 2 Water pump 3 Oil filler neck 4 Oil separator valve for crankcase breather 5 Tandem fuel filter 6 Fuel lift pump with prestrainer 7 Injection pump 8 Oil drain plug 9 Oil dipstick 10 Oil cooler 11 O...

Page 16: ...Technical information 14 Engine views D 2866 LE LXE 1 2 3 4 5 6 7 8 9 10 11 12 13 14...

Page 17: ...rator valve for crankcase breather 3 Tandem fuel filter 4 Fuel lift pump with prestrainer 5 Injection pump 6 Oil dipstick 7 Alternator 8 Water pump 9 Tensioning pulley 10 Oil filter 11 Water drain plu...

Page 18: ...el below the crankshaft centre line The engine has replaceable wet cylin der liners and individual cylinder heads with shrunk in valve seat rings and replaceable valve guides Piston Conrod Crank assem...

Page 19: ...el end 6 2 5 4 1 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 mark...

Page 20: ...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 bearin...

Page 21: ...lube oil is cleaned in a full flow oil filter Depending on the agreed extent of delivery and the design of the engine the lube oil cir cuit can be equipped with oil pressure monitors advance warning...

Page 22: ...eder screw 6 Injection pump 7 Overflow valve 8 Injection nozzles 9 Suction line 10 Return line Injection pump The in line injection pump is driven via gears from the crankshaft It is connected to the...

Page 23: ...the turbine rotor of the turbochar ger Air impeller mounted on the same shaft draws in fresh air and delivers it at a higher pressure to the cylinders The turbocharger is air cooled or liquid cooled L...

Page 24: ...cooler The intercooler has to be removed from the engine for cleaning Cooling The engine has a liquid cooling system The water pump is a maintenance free impeller pump driven by V belts from the crank...

Page 25: ...above all against moisture Operate the alternator according to the instructions given in the chapter Commis sioning and operation Starter motor The sliding gear starter motor is flanged to the rear of...

Page 26: ...visible on dipstick D After refilling with oil rotate the engine with the starter and move the shut down lever to stop at the same time until the oil pressure warning light goes out and the oil pressu...

Page 27: ...riods without use press shut down lever in stop position and operate starter motor for a few sec onds max 10 until oil pressure is indicated Only then the engine should be started in the normal way Ru...

Page 28: ...aid connections with ground not even by briefly bringing the connections into contact D Do not operate the alternator without battery connection Shutting down Disengage the gearbox clutch and move the...

Page 29: ...Refilling with oil Refill with fresh engine oil at the oil filler neck 1 1 Oil filler neck on valve cover After refilling with oil rotate the engine with the starter and move the shut down lever to st...

Page 30: ...elector lever in any in termediate position because this would be liable to interfere with oil supply Renewal of filter cartridges D Allow the filter content to run off along drain plugs Hold a suitab...

Page 31: ...mend that you have faults in the injection pump rectified only in an authorised specialist workshop Bleeding the fuel system Bleeding the fuel filters is by releasing the bleed screws and operating th...

Page 32: ...filter felt tube element Fit new seals D Operate manual fuel lift pump until fuel is emitted without any bubbles D Close vent plug on primary filter D Bleed secondary filter in the same manner Parall...

Page 33: ...s dan gerous waste and must be disposed of accordingly Change over fuel filter with filter car tridges replaced by change over fuel filter with interchangeable filter Where the changeover type filter...

Page 34: ...gh sludge drain plug D Take off filter cover on slackening fixing nut D Withdraw filter element and flush filter chamber with clean fuel D Install new element D Fit filter cover using new gasket D Fil...

Page 35: ...the cylinder head Note for cleaning nozzles with Bosch cleaning set KDEP 2900 Clean nozzle body externally from soot and carbon When cleaning several nozzles at the same time make sure nozzle bodies a...

Page 36: ...t hold your hands under the fuel jet as there is a risk of injury Do not inhale the atomised fuel If possible work under an extraction system Installation Clean seat in cylinder head Insert nozzle hol...

Page 37: ...st be added at the filler neck only Do not put cold coolant into an engine which is warm from operation Ensure that the ratio of water to anti freeze is correct Find the cause of the loss of coolant a...

Page 38: ...wn di rectly from behind Do not use high pressure cleaners steam sprayers may be used Henkel P3 begesol contains no toxic or corrosive substances and if handled properly may be used without hesitation...

Page 39: ...luid and pickle the en gine for another 8 hours D Drain the pickling fluid fill the system with tap water and run the engine at idle for 5 minutes to flush out all fluid then drain the water D Fill th...

Page 40: ...r caps and working valves of cool ing system The rubber gaskets of the filler caps and working valves negative pressure and positive pressure valves of the cooling system are subject to natural aging...

Page 41: ...t tilt it so that it jams and clean it in solvent diesel oil petroleum ether using a brush If the air compressor should be badly fouled it is recommended that the wheel be allowed to soak in a vessel...

Page 42: ...er it is necessary to clean it at regular intervals which depend on the quality of the coolant used For this purpose dismantle the inter cooler In almost all cases it will suffice to clean the individ...

Page 43: ...tor Ensure that the lid and the collector are reassembled correctly A lug on the collec tor fits into a recess in the edge of the lid If the filter is installed horizontally note the oben top marking...

Page 44: ...ent is avail able Blowing out wear goggles To do this fit a pipe to the compressed air gun The end of the pipe should be bent by approx 90 The pipe must be long enough to reach the bottom of the car t...

Page 45: ...iced changed the contamination gauge responds again immediately D if the main cartridge is defective When the main cartridge has been re moved the safety cartridge is accessible and can be removed als...

Page 46: ...adjusting the pointer after the vibration damper has been removed or replaced In other words before the vibration damper with the scale disc is installed the engine should be positioned at OT top dead...

Page 47: ...should be set by means of the degrees scale on the flywheel To check and set the start of deliv ery with start of delivery indicator in the governor housing by authorized specialist personnel 2 1 3 1...

Page 48: ...exactly whether or not the pump is at start of delivery only by means of the following special tools a Light signal transmitter 80 99605 6002 2 1 Push light signal transmitter into socket in governor...

Page 49: ...centre of the 3 mm bore in the sleeve Setting start of delivery If the start of delivery as determined in the checks carried out in accordance with method a or b is not correct proceed as follows Rem...

Page 50: ...istons are just rocking Valve rocking on cylinder 1 5 3 6 2 4 6 2 4 1 5 3 Adjust valves on cylinder In order to enable the engine to be rotated manually during adjustments there is a plate with a cent...

Page 51: ...7801 0211 After the first 400 hours of operation re tighten cylinder head bolts 1 to 4 in the order shown in Tightening diagram 1 by a further 90 1 4 revolution The two outer screws intake and exhaust...

Page 52: ...ng cylinder head bolts after repairs engine cold or warm by authorized specialist personnel After the first 10 to 20 hours of operation after a repair turn the cylinder head bolts by a further 90 1 4...

Page 53: ...or bolts elon gated beyond the maximum permissible length must immediately be made unus able e g by destroying the threads with a hammer and scrapped V belts The tension of the V belts should be check...

Page 54: ...remains in its position Drive Tensioning forces according to the kg graduation on the tes ter Drive belt New installation When servicing width Installa tion After 10 min run ning time servicing after...

Page 55: ...Notes 53...

Page 56: ...TDC Intake closes 49 after BDC Exhaust opens 47 before BDC Exhaust closes 9 after TDC Fuel system Injection In line pump with flange fastening Governor All speed type Injection timer Automatic centri...

Page 57: ...uring operation depend ing on oil temperature oil viscosity class and engine rpm monitored by oil pressure monitors or dis plays Oil filter Full flow filter with two paper cartridges Engine cooling sy...

Page 58: ...lve timing Intake opens 23 before TDC Intake closes 37 after BDC Exhaust opens 60 before BDC Exhaust closes 30 after TDC Fuel system Injection In line pump with flange fastening Governor All speed typ...

Page 59: ...uring operation depend ing on oil temperature oil viscosity class and engine rpm monitored by oil pressure monitors or dis plays Oil filter Full flow filter with two paper cartridges Engine cooling sy...

Page 60: ...0 25 mm Exhaust 0 40 mm Valve clearance changed Starting from engine no 5264038 in engines with 2 cylinder air compressors and or power take off starting from engine no 5274086 D 2866 LE only Intake...

Page 61: ...rpm variable 51 11102 7659 15 1800 rpm variable 51 11103 7075 18 2100 rpm variable 51 11102 7657 15 2100 rpm variable 51 11103 7084 20 2200 rpm variable 51 11102 7656 15 2200 rpm variable 51 11103 707...

Page 62: ...33 Intercooler 22 40 L Lubricating oil filter 27 M Maintenance and care 27 43 Marking the dipstick 24 N Nameplates 4 O Oil cooler 19 Oil drainage 27 Oil level 27 P Piston Conrod Crank assembly 16 Prep...

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Page 64: ...MAN Nutzfahrzeuge Aktiengesellschaft Vogelweiherstra e 33 D 90441 N rnberg Printed in Germany 51 99493 8264 GB...

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