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1. Manuals
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3. Man Manuals
4. Engine
5. D 2866 E
6. Operating instructions manual

• Page 1
  Operating Instructions Diesel Engine D 2866 E D 2866 TE D 2866 LE D 2866 LXE…
• Page 3
  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 re- pair work.

• Page 4: Table Of Contents

  Index Declaration …………. . . Nameplates .

• Page 5: 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.

• Page 6: Nameplates

  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 MAN Nutzfahrzeuge Aktiengesellschaft spare parts catalog to distinguish between spare parts). Motor-Nr. / Engine No. NI/II Enter 14-digit engine serial number.

• Page 7: Safety Regulations

  D Do not touch the engine with bare hands when it is warm from operation – risk of burns. D Exhaust gases are toxic. Comply with the instructions for the installation of MAN Die- sel engines which are to be operated in enclosed spaces. Ensure that there is ad- equate ventilation and air extraction.

• Page 8
  Safety regulations During maintenance and care D Always 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. D Change the oil when the engines is warm from operation.
• Page 9
  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 result- ing from the installation of other parts which are supposedly “just as good”.
• Page 10
  Safety regulations D Comply with instructions for operation of the alternator. See “Commissioning and oper- ation”. D Do 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 D Take old oil only to an old oil collection point.
• Page 11
  Safety regulations D After washing apply a fatty skin cream to the skin. D Change oil-soaked clothing and shoes. D Do 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.

• Page 12: Technical Information

  Technical information Engine views D 2866 E…

• Page 13
  Technical information 1 Tensioning pulley 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 Oil cooler 12 Oil filter 13 Starter motor…
• Page 14
  Technical information Engine views D 2866 TE…
• Page 15
  Technical information 1 Tensioning pulley 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 Oil filter 12 Turbocharger 13 Starter motor…
• Page 16
  Technical information Engine views D 2866 LE, LXE…
• Page 17
  Technical information 1 Oil filler neck 2 Oil separator 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 plug 12 Oil drain plug 13 Turbocharger…

• Page 18: Engines

  Technical information Engines The engines D 2866 E / TE / LE / LXE are in-line vertical liquid-cooled 6-cylinder four- stroke 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.

• Page 19
  Technical information Engine timing Camshaft, oil pump and injection pump are driven by a gear train arranged at the fly- wheel end. 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”…

• Page 20: Engine Lubrication

  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.

• Page 21
  Technical information The injection pump and the turbocharger are also connected to the engine lubricating system. The cylinder walls and timing gears are splash-lubricated. Each cylinder has an oil jet provided for cooling the underside of the pistons. The 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 and cut-off function) which shut the engine down in the event of a sudden loss of pressure.

• Page 22: Fuel System

  Technical information Fuel system The fuel is delivered by the fuel lift pump via the fuel filter to the injection pump and from there to the injectors. The fuel is sprayed into the cylinder through four-hole nozzles fitted in screw-fit injectors in the cylinder heads.

• Page 23: Turbocharger

  Technical information Fuel filters Before entering the suction chamber of the injection pump, the fuel is cleaned in a two- stage, parallel or changeover filter. Turbocharger (D 2866 TE, LE, LXE) The exhaust gases of the engine are passed through the turbine rotor of the turbochar- ger.

• Page 24: Intercooler

  Technical information Intercooler (D 2866 LE, LXE) Before entering the cylinders the combustion air compressed in the turbocharger is passed through a heat exchanger (intercooler). Heat removal in the cooler is either by air (air-to-air intercooler) or, in case of the marine application, by means of seawater (air-to-water intercooler) delivered by the raw water pump.

• Page 25: Electrical Equipment

  Technical information Electrical equipment Alternator The alternator is fitted with integral silicon rectifiers. A transistorized regulator mounted on the alternator limits the alternator voltage. The al- ternator should not be operated except with the regulator and battery connected in circuit to avoid damage to the rectifier and regulator.

• Page 26: Commissioning And Operation

  “Technical Information down lever to “stop” at the same time for the installation of MAN Diesel en- until the oil pressure warning light goes gines”. out and the oil pressure gauge shows a pressure.

• Page 27: Starting

  Commissioning and operation Raw water pump Running in Do not let raw water pump run dry. It is recommended that new or overhauled Make sure that all valves / cocks in the engines should not be operated at a load raw water circuit are open.

• Page 28: Shutting Down

  Temporary anti-corrosion protection ac- into contact! cording to MAN works norm M 3069 is re- D Do not operate the alternator without quired for engines which are to be put out battery connection! of service for fairly long periods.

• Page 29: Maintenance And Care

  Maintenance and care Engine lubrication Oil level Check the oil level in the engine sump daily with a dipstick. The level should be between the two notches cut into the dip- stick and should never be allowed to drop below the lower notch. Caution: Do not add so much engine oil that the 1 Oil filler neck on valve cover…

• Page 30
  Maintenance and care Observe positions of selector lever! Continuous operation (both filter halves in operation) Right-hand filter cut out Left-hand filter cut out 1 Oil drain plug 2 Oil filter bowl Caution: 3 Tie screw Do not leave selector lever in any in- 4 Filter cartridge termediate position because this 5 Gasket…

• Page 31: Fuel System

  Maintenance and care Fuel system Fuel lift pump The fuel lift pump is operated by the injec- Fuel tion pump camshaft via the roller tappet. If Diesel fuel which contains moisture is used the injection system and the cylinder Strainer liners / pistons will be damaged.

• Page 32
  Maintenance and care Two-stage fuel filter Parallel fuel filter with filter cartridges (replaced by parallel fuel filter) (replaced by parallel filter with inter- changeable filter) In two filter housings connected in series the fuel first passes through a felt tube el- The fuel passes through two filter el- ement and then through a paper element.
• Page 33
  Maintenance and care Parallel fuel filter with interchangeable Change-over fuel filter with filter car- filter tridges (replaced by change-over fuel filter with The fuel flows through two parallel filters. interchangeable filter) Where the changeover-type filter is in- stalled, the servicing procedure is for the filter side requiring to be shut off with the engine running.
• Page 34
  Maintenance and care Change-over fuel filter with inter- Caution: changeable filter Do not leave selector lever in any in- termediate position because this would be liable to interfere with fuel supply. If in doubt stop the engine to change the fuel filter. Continuous operation (both filter halves in operation)
• Page 35
  Maintenance and care Injector maintenance Removal, dismantling and cleaning (by authorized specialist personnel) Unscrew delivery pipe at nozzle holder and at the injection pump. Remove leak-off pipe. Release union screw of nozzle holder with special wrench. Remove nozzle holder with gasket from the cylinder head.
• Page 36
  Maintenance and care Before reassembly thoroughly wash Caution: nozzle body and needle in clean test oil. Do not hold your hands under the fuel jet, as there is a risk of injury. Do not Hold the needle at the pintle end only; to inhale the atomised fuel.

• Page 37: Cooling

  See Publication “Fuels, Lubricants and Coolants for MAN Diesel Engines”. Filling-in of coolant (only when engine has cooled down) D Fill in the coolant slowly…

• Page 38
  HENKEL a) Drain coolant P3-begesol. This cleansing agent is avail- b) Open thermostats positively (use short- able from MAN in 10-kg cans under Part circuit inserts), so that the entire cool- No. 09.21002-0164. ant circuit is flushed in the cleaning…
• Page 39
  Maintenance and care d) Warm up engine under load. After a D Drain the pickling fluid, fill the system temperature of 60°C is reached, run with tap water, and run the engine at engine for a further 15 minutes idle for 5 minutes to flush out all fluid; e) Drain cleaning fluid then drain the water f) Repeat steps c) and d)
• Page 40
  Maintenance and care D Fill the container with undiluted original Filler caps and working valves of cool- pickling fluid at room temperature (Lith- ing system solventsäure or engine pickling fluid The rubber gaskets of the filler caps and RB-06) until the tube bundle is com- working valves (negative pressure and pletely immersed positive pressure valves) of the cooling…

• Page 41: Turbocharger

  Maintenance and care Turbocharger This precaution will enable any wear of the bearings to be detected in good time before serious damage is caused to the Maintenance rotor and bearings. (by authorized specialist personnel) The turbochargers do not call for any spe- Measuring of axial clearance cific maintenance.

• Page 42: Intercooler

  Maintenance and care Intercooler Maintenance (by authorized specialist personnel) In order to maintain the heat transfer effi- ciency of the intercooler, 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.

• Page 43: Air Cleaner

  Maintenance and care Air cleaner Fouling Indicator As the degree of clogging increases the Dry air cleaner red indicator becomes more and more vis- ible in the transparent section of the air cleaner. If the fouling indicator remains engaged, i.e. it still shows completely red even with the engine shut down, the filter cartridge must be cleaned or replaced.

• Page 44
  Maintenance and care Changing the filter cartridge Blowing out (wear goggles) To do this fit a pipe to the compressed air Caution: gun. The end of the pipe should be bent No dust must get to the clear air end. by approx.
• Page 45
  Maintenance and care Viscous air cleaner On no account re-use damaged car- tridges. If in doubt fit a new cartridge. Safety cartridge The maintenance intervals for filters de- When the main cartridge is being serviced pend on the respective operating condi- the safety cartridge remains in the filter tions.

• Page 46: Checking And Setting

  Checking and setting To check and set the start of deliv- The pointer should then be aligned such that its measuring edge exactly coincides ery with start of delivery marker with the “OT” mark on the scale disc. on injection pump hub (by authorized specialist personnel) In order to enable the engine to be rotated manually during adjustments, there is a…

• Page 47
  Checking and setting Setting start of delivery To check and set the start of deliv- ery with start of delivery indicator Correct start of delivery by turning the in the governor housing pump hub in the slotted holes of the drive (by authorized specialist personnel) gear.
• Page 48
  Checking and setting The pointer should then be aligned such Connect up power supply of light signal that its measuring edge exactly coincides transmitter (red terminal = +). Turn engine with the “OT” mark on the scale disc. by hand so that piston in cylinder no. 1 in the compression stroke comes close to In order to enable the engine to be rotated the start of delivery.
• Page 49
  Checking and setting Setting start of delivery 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 proce- dure. b. Sleeve If a light signal transmitter is not available, good measurement results can also be achieved with a plug-in receptacle.

• Page 50: To Check And Adjust Valve Clearance

  Checking and setting To check and adjust valve clear- ance (by authorized specialist personnel) The valve clearance for new and over- hauled engines should be checked after the first 10 to 20 hours of operation. Then it should be adjusted every 400 hours of operation.

• Page 51
  Checking and setting Retightening cylinder head bolts Remove the sticker “First retightening of cylinder head bolts …” and attach the on new engines sticker “Second retightening of cylinder (engine cold or warm) head bolts …” to show that the cylinder by authorized specialist personnel head bolts have been retightened for the second time.
• Page 52
  Checking and setting Tightening cylinder head bolts Retightening cylinder head bolts after a repair after repairs (engine cold) (engine cold or warm) by authorized specialist personnel by authorized specialist personnel Before inserting the cylinder head bolts oil After the first 10 to 20 hours of operation them with engine oil on the thread (not to after a repair turn the cylinder head bolts the bore) and coat the contact face of the…

• Page 53: V-Belts

  Checking and setting Re-using old cylinder head bolts V-belts Checking The tension of the V-belts should be Before re-using old cylinder head bolts checked after every 200 hours of oper- check them as follows: ation. Length Change the V-belts if necessary During tightening the bolts are intention- If, in the case of a multiple belt drive, wear ally stressed beyond the yield point and…

• Page 54
  Checking and setting Tension and / or replace V-belts D Slowly depress pad  until the spring can be heard to disengage. This will Water pump – Alternator cause the indicator to move upwards D Remove fixing bolts À If pressure is maintained after the spring D Remove lock-nut Á…
• Page 55
  Notes ……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

• Page 56: Technical Data

  Technical data Model D 2866 E Design in-line vertical Cycle 4-stroke Diesel Combustion system Direct injection Number of cylinders Bore 128 mm Stroke 155 mm Swept volume 11 967 cm Compression ratio 17.5 : 1 Rating see engine nameplate Firing order 1–5–3–6–2–4…

• Page 57
  Technical data Engine lubrication Force feed Oil capacity in oil sump (litres) min. max. Deep 12 l 18 l Shallow 14 l 20 l For 30° tilt 12 l 18 l Oil pressure during operation (depend- monitored by oil pressure monitors or dis- ing on oil temperature, oil viscosity plays class and engine rpm)
• Page 58
  Technical data Model D 2866 TE Design in-line vertical Cycle 4-stroke Diesel with turbocharger Combustion system Direct injection Turbocharging Turbocharger Number of cylinders Bore 128 mm Stroke 155 mm Swept volume 11 967 cm Compression ratio 15.5 : 1 Rating see engine nameplate Firing order 1–5–3–6–2–4…
• Page 59
  Technical data Engine lubrication Force feed Oil capacity in oil sump (litres) min. max. Deep 12 l 18 l Shallow 14 l 20 l For 30° tilt 12 l 18 l Oil pressure during operation (depend- monitored by oil pressure monitors or dis- ing on oil temperature, oil viscosity plays class and engine rpm)
• Page 60
  Technical data Model D 2866 LE, LXE Design in-line vertical Cycle 4-stroke Diesel with turbocharger and in- tercooler Combustion system Direct injection Turbocharging Turbocharger with intercooler Number of cylinders Bore 128 mm Stroke 155 mm Swept volume 11 967 cm Compression ratio D 2866 LE 15.5 : 1…
• Page 61
  Technical data Injection timer Automatic centrifugal type in camshaft drive gear Injectors 4-orifice nozzles Opening pressure of injector Injector + injection nozzle New nozzle holder: Used nozzle holder: 51.10101-7274 220 + 8 bar 220 + 8 bar 51.10101-7290 235 + 8 bar 220 + 8 bar 51.10101-7338 295 + 8 bar…

• Page 62: Index

  Index Air cleaner ……22, 41–43 Nameplates ……. Alternator .

• Page 64
  MAN Nutzfahrzeuge Aktiengesellschaft Vogelweiherstraße 33 D–90441 Nürnberg Printed in Germany 51.99493–8264…