MAN Industrial Diesel Engine D2876 LE201, D2876 LE202, D2876 LE203 Service Repair Workshop Manual

Preface 1 This Repair Manual is designed to facilitate competent repair of the engines listed here in. In addition to this Repair Manual the following publications are available: D Operating Instructions D Fuels, Lubricants and Coolants for MAN Diesel Engines D Spare-parts catalogue D Service record book with maintenance plan 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. It is compulsory that the engine be removed before performing any of the work describe in this Repair Ma- nual. The expert knowledge necessary for handling Diesel engines was taken for granted when this publication was compiled. Note: Only use fuel, coolants and lubricants in accordance with MAN’s regulations otherwise the manufacturer’s warranty will not apply! For basic information on the fuels see the publication “Fuels, Lubricants and Coolants for MAN Diesel Engines”. You can find the approved products in the internet under: http://www.man-mn.com/ " Products & Solutions " E-Business Any repair of components such as injection pump, alternator etc. ought to be left to our or the manufacturer’s service department. Best regards MAN Nutzfahrzeuge Aktiengesellschaft Nuremberg Plant Since our products are in continuous development, we reserve the right to make technical modifications. © 2006 MAN Nutzfahrzeuge Aktiengesellschaft Reprinting, copying or translation, even of extracts, is not allowed without written permission from MAN. All rights under the copyright law are strictly reserved by MAN. MTDB Technical status: 03.2006 51.99598−8166

Instructions 2 Important instructions which concern technical safety and protection of persons are emphasised as shown below. Danger: This refers to working and operating procedures which must be complied with in order to rule out the risk to persons. Caution: This refers to working and operating procedures which must be complied with in order to prevent damage to or destruction of material. Note: Explanatory descriptions which help in understanding the relevant work or operating procedure to be carried out. Assembly of pipes Danger: No pipes may be bent. Risk of breakage! Fitting flat seals / gaskets Flat seals / gaskets are often inserted with sealing agents or adhesives to make fitting them easier or to achieve better sealing. Flat seals may slip in operation due to the “sewing -machine” effect, in particular if they are used between parts with different rates of linear expansion under heat (e.g. aluminium and cast iron), and leaks may then occur. Example: The cap of the front crankshaft seal. If a sealing agent or an adhesive is used here the flat seal will move inwards in the course of time as a result of the different expansion rates of the materials. Oil will be lost, for which the shaft seal may be thought to be responsible. Flat seals / gaskets can be fitted properly only if the following points are observed: D Use only genuine MAN seals / gaskets D The sealing faces must be undamaged and clean D Do not use any sealing agent or adhesive − as an aid to fitting the seals a little grease can be used if necessary so that the seal will stick to the part to be fitted D Tighten bolts evenly to the specified torque Fitting round sealing rings D Use only genuine MAN round sealing rings D The sealing faces must be undamaged and clean D Always wet round sealing rings with engine oil before fitting them

Contents 3 Preface 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instructions 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine type classification 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety regulations 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault table 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General notes on engine overhaul 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commissioning after engine overhaul 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine views 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic diagram of engine lubrication 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic diagram of cooling system 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic diagram of fuel system 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic diagram of engine timing 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel system Removing and installing high-pressure pump 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing the high-pressure lines 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing the rail 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing the injectors 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel prefilter 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing the Fuel Service Centre, replacing the filter cartridge 36 . . . . . . . . . . . . . . . . . . Cooling system Draining and filling coolant 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing thermostats 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing expansion tank 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing coolant pump 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing coolant pump 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning cooling system 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing heat exchanger 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing pipe cluster for heat exchanger 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning heat exchanger pipe cluster 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing sea water pump 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing/installing/stripping seawater pump 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing impeller of sea water pump 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication Changing oil filter 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing the oil cooler 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing, repairing oil pump 64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing oil injection nozzle 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel / Crankshaft seal Removing and fitting vibration damper, replacing front crankshaft gasket 69 . . . . . . . . . . . . . . . . . . . . . . Removing and installing flywheel, replacing starter gear ring 73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing crankshaft seal (flywheel end) 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the bearing race 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft seals 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake / exhaust system Removing and installing intake pipes 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing exhaust pipe 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger, troubleshooting 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing turbocharger 83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Waste gates 85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing intercooler 86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents 4 Cylinder head Removing and installing cylinder head 89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting the valve clearance 93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling the rocker arm mechanism 94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing valves 98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing valve guides 104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing valve seat insert 105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reworking valve seat 107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refacing valves 110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking compression 111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve timing Removing and installing the timing case 114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing camshaft 116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing camshaft bearing bushes 118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the valve timing 127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankgear, pistons Removing and installing crankshaft 128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing pistons with conrods 131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing pistons from conrod and fitting, checking − replacing conrod 134 . . . . . . . . . . . . . . . . . . . . . . . Removing and installing piston rings 136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing cylinder liners 138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring piston protrusion 142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attachments Removing and installing starter motor 143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and attaching alternator 144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-belts 145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase breather (oil separator) 147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Data 149 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine − Technical data 150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase 151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder liner 151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft 152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel and starter gear ring 154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conrod 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conrod bearing 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pistons 156 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder head 157 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve train 159 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine lubrication 162 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling system 163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger 165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel system 166 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter motor 167 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator 167 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque guide values 168 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special tools 173 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index 187 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine type classification 5 All the engines dealt with here are related in terms of their design and make up a family. The type classification, which is made up of a series of letters and numbers, reveals some of the features of the engine in question provided the reader is familiar with the underlying nomenclature. The system is explained below using the model type D 2876 LE 423 as an example: D The “D” at the start of the type classification stands for “Diesel” 28 The numbers “28” indicates that the power plant in question has a bore of 128 mm 7 The “7” means 166 mm stroke 6 The “6” indicates the number of cylinders 6 L This letter stands for “charge-air cooling” (German: Ladeluftkühlung) E The “E” stands for “fitted engine” (German: Einbaumotor) and is intended to distinguish MAN vehicle engines 423 This is a factory-internal development number

Safety regulations 6 General notes Important safety regulations are summarized in this quick-reference overview and arranged by topic to ef- fectively convey the knowledge necessary to avoid accidents causing injury, damage or environmental hazard. Additional information can be found in the operating instructions of the engine. Important: Should an accident occur despite all precautionary measures, particularly one involving contact with corros- ive acid, penetration of fuel under the skin, scalding by hot oil, antifreeze splashing into the eyes etc. you must seek medical assistance immediately. 1. Regulations for the prevention of accidents with personal injury Inspection, adjustment and repair work may only be performed by authorised and skilled personnel. D During installation work, switch off the battery master switch. D When carrying out maintenance and repair work, ensure that the engine cannot be accidentally started from the bridge by unauthorised persons. D The engine may only be started and operated by authorised personnel. D When the engine is running, do not get too close to the rotating parts. Wear close-fitting working clothes. D Do not touch hot engine with bare hands: Risk of burns. D Keep area surrounding engine, ladders and stairways free of oil and grease. Accidents caused by slipping can have serious consequences. D Only work with tools which are in good condition. Worn spanners / wrenches slip: Danger of injury. D Persons must not stand under an engine suspended on a crane hook. Keep lifting gear in order. D Open the coolant circuit only when the engine has cooled down. If opening the coolant circuit while the engine is hot is unavoidable, observe the instructions in the chapter “Maintenance and care” in the Operator’s Manual. D Do not tighten or undo pipes and hoses under pressure (lubricating oil circuit, coolant circuit and any downstream hydraulic oil circuits). The fluids which flow out can cause injury.

Safety regulations 7 D When working on the electrical system, first disconnect the earth cable of the battery and reconnect this last to prevent short circuits. D Follow the manufacturer’s instructions for handling batteries. Caution: Accumulator acid is toxic and caustic. Battery gases are explosive. D When performing welding work, observe the “Notes for welders”. 2. Regulations designed to prevent damage to 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 If engine operation is disrupted, immediately determine the cause and have it remedied to prevent additional damage. 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 allow the engine to run dry, i.e. without lubricant or coolant. Appropriate notices must be attached to engines that are not ready for operation. D Today modern components of diesel injection consist of high-precision parts which are exposed to ex- treme stresses. The high-precision technology requires the utmost cleanliness during all work on the fuel system. Even a particle of dirt over 0.2 mm can lead to the failure of components. D Use only MAN-approved service products (fuel, engine oil, anti-freeze and anti-corrosion agent). Pay attention to cleanliness. Diesel fuel must be free of water. D Do not fill engine oil beyond the max. notch on the dipstick. Do not exceed the maximum per- missible tilt of the engine. Serious damage to the engine may result if these instructions are not adhered to. D Control and monitoring devices (charge control, oil pressure, coolant temperature) must be in perfect working order. D Observe the instructions for operating the alternator; see chapter “Maintenance and care” in the Oper- ator’s Manual.

Safety regulations 8 3. Regulations for the prevention of environmental damage Engine oil and filter elements / cartridges, fuel / fuel filter D Old oil must be passed on for recycling. D Take strict precautions to ensure that no oil or Diesel fuel gets into the drains or the ground. Caution: Risk of contamination of potable water. D Filter elements are classed as dangerous waste and must be treated as such. Coolant D Treat undiluted corrosion protection agents and / or antifreeze as hazardous waste. D When disposing of used coolant, the regulations issued by the relevant local authorities must be observed. 4. 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- ritation or inflammation of the skin may therefore occur. Used engine oil also contains hazardous sub- stances that have caused skin cancer in tests on animals. If the basic principles of work safety and hygiene are observed, handling used engine oil does not represent a health hazard. Precautionary measures to protect your health: D Avoid prolonged or repeated skin contact with used engine oil. D Protect your skin by means of suitable agents (creams etc.) or wear protective gloves. D Clean skin which has been in contact with engine oil. − Wash thoroughly with soap and water. A nail brush provides effective assistance here. − Special hand cleaning agents make it easier to clean dirty hands. − Do not use petrol (gasoline), diesel fuel, gas oil or solvents as washing agents. D After washing apply a fatty skin cream to the skin. D Change clothing and shoes that are soaked in oil. D Do no put oily cloths in you pockets. Ensure that used engine oil is disposed of in the appropriate manner. − Engine oil is a substance that endangers the water supply − For this reason do not let engine oil get into the ground, waterways, the drains or the sewers. Violations are punishable. Carefully collect and dispose of used engine oil. Information on collection points can be obtained from sales personnel, the supplier or the local authorities. ∗ Based on “Information sheet for handling used engine oil”.

MAN Industrial Diesel Engine D2876 LE201, D2876 LE202, D2876 LE203 Service Repair Workshop Manual

You're Reading a Preview

Recently Viewed