Man D 2866 E User manual

Operating Instructions
Diesel Engine
D 2866 E
D 2866 TE
D 2866 LE
D 2866 LXE

Preface
1
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 envi-
ronmental 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 re-
pair 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 per-
mission of MAN. MAN explicitly reservs all rights according to copyright law.
MTDA Technical status: 11.1998 51.99493–8264

Index
2
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For data see original declaration
If required this declaration is
enclosed with the delivery note.
Declaration
3
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:
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 ma-
chine 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

Nameplates
4
Model
......................................................................
delivered on
......................................................................
installed on
......................................................................
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.
Enter 6-digit job number
(Order number).
MAN Nutzfahrzeuge Aktiengesellschaft
Typ
Motor-Nr. / Engine No.
NI/II
Temp. C
Werk Nürnberg Germany
:
MAN Nutzfahrzeuge AktiengesellscMAN Nutzfahrzeuge Aktiengesellschaft
:
:
Altitude mRating BHP
Job No Rating kW Speed rpm
Serial NoModelYear
–0219
Aufstellhohe m uNNLeistg. PS
Drehz. 1/min
Leistung kWWerk–Nr.
Motor–Nr.TypBauj.
°

Safety regulations
5
General notes
Handling diesel engines and the necessary resources is no problem when the per-
sonnel 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 per-
sons, 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 instruc-
tions 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 Die-
sel engines which are to be operated in enclosed spaces. Ensure that there is ad-
equate ventilation and air extraction.
DKeep vicinity of engine, ladders and stairways free of oil and grease.
Accidents caused by slipping can have serious consequences.

Safety regulations
6
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 en-
sure 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.

Safety regulations
7
DWhen checking injectors do not put your hands under the jet of fuel. Do not inhale ato-
mised 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 result-
ing 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 pres-
sure, coolant temperature) function satisfactorily.

Safety regulations
8
DComply with instructions for operation of the alternator. See “Commissioning and oper-
ation”.
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 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, irritation or inflammation of the skin may therefore occur. Used engine oil
also contains dangerous substances which have caused skin cancer in animal experi-
ments. 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.

Safety regulations
9
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 asbes-
tos. Spare parts and, where necessary, their packaging
is marked accordingly (see illustration below).
DWhen parts that contain asbestos are machined fine as-
bestos dust may be released. To prevent possible dam-
age to health please take appropriate safety precautions
and follow the advice given below:
DWherever possible work in the open air or in well venti-
lated 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.
DWet the dust, put it into a tightly closing container and have it disposed of as danger-
ous waste.
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Innånding av stov
ACHTUNG
ENTHÄLT
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CONTEM
AMIANTO
Respirrar po de
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Consulte as normas
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VAROITUS
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ASBESTIA
Asbestipölyn
hengittäminen on
terveydelie
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Noudattakaa
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VOORZICHTIG
BEVAT
ASBEST
Het inademen van
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Houdt u aan de
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Respirer la
CONTIENT DE
L’AMIANTE
poussière d’amiante
est dangereux
pour la santé
Suicre les consignes
de sécurite
ARTIKELN
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INNEHÅLLER
ASBEST
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Innehåller
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INNEHOLDER
ATTENZIONE
Resirare polvere di
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Seguire le norme
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PRECAUCIÓN
Evitese ta
WARNING
Breathing asbestos
CONTAINS
ASBESTOS
dust is dangerous
to health Follow
safety Instructions
:CONTIENE
AMIANTO
generación
de polvo

Technical information
10
Engine views D 2866 E
12 3 4 5
7689
10111213

Technical information
11
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

Technical information
12
Engine views D 2866 TE
6789
1
2
4
5
3
10111213

Technical information
13
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

Technical information
14
Engine views D 2866 LE, LXE
123
4567
8
91011121314

Technical information
15
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
14 Starter motor

Technical information
16
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.
Engine block
The cylinder block is a single piece of alloy cast iron. To increase its stiffness, it is ex-
tended to a level 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 assembly
The forged crankshaft has screwed-on counterweights. Radial seals with replaceable
wearing rings on crankshaft and flywheel are provided to seal the crankcase penetra-
tions.
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 steel-
backed lead bronze ready-to-fit type bearings.

Technical information
17
Engine timing
Camshaft, oil pump and injection pump are driven by a gear train arranged at the fly-
wheel 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-marked by “1” or “D”.
Valves
The overhead valves are actuated via chilled cast iron tappets, push rods and rocker
arms from the camshaft.

Technical information
18
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.
1234
5
6
7
8
9
10
1 Oil suction pipe 7 Oil filter
2 Main oil galleries 8 Turbocharger
3 Jets for piston cooling and cam lubrication (D 2866 TE / LE / LXE only)
4 Oil pump 9 Oil cooler
5 Oil relief valve 10 Injection pump
6 Bypass valve