MAN D2866-LE D2876-LE Marine Diesel Engine Repair Manual

Preface 1 This Repair Manual is designed to facilitate repair of the engines listed in line with accepted technical prin- ciples. 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 associated 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 Man- ual. 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 We reserve the right to make technical modifications in the course of further development. © 2005 MAN Nutzfahrzeuge Aktiengesellschaft Reprinting, duplication or translation, in whole or in part, is not permitted without the written permission of MAN. MAN reserves all rights accorded by the relevant laws on copyright. MTDB Technical status: 05.2005 51.99493−8428

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

1 2 3 4 Instruction 3 Masking of fuel and lube oil pipe con- nections (for classified engines only) The unions of pressurised oil and fuel pipes are masked with a protective tape. If this tape is removed during a repair, the unions must be masked with protective tape again after- wards. The following pipes are affected: − Oil supply pipe to turbochargers − Fuel pipes between supply pump, filter and injection pump − Injection pipes protected against leaks Fig. 1 A protective tape is wound around the unions. En- sure that there is 50 % overlap on every pass. Figs. 2−4 The unions to be masked must be clean and free of oil and grease. Do not apply the protective tape unless this is the case

Contents 4 Preface 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instruction 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety instruction 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General information on the overhaul of engines 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trouble shooting table 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine views, D 2866 LE401 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cross section of engine 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Longitudinal section 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic diagram of engine lubrication system 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic diagram of fuel system 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic diagram of cooling system 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel system Checking and adjusting start of fuel delivery 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing injection pump 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel injectors 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking and repairing fuel injectors 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning fuel prefilter 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing fuel filter cartridges 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling system Draining and filling with coolant 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing thermostat 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing water pump 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing water pump 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembling water pump 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and attaching expansion tank 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing heat exchanger 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing heat-exchanger pipe set 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Raw water pump 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication Changing oil filter 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing oil cooler 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing oil pump 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil spray nozzle 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel / Crankshaft seal Removing and installing vibration damper, changing front crankshaft seal 60 . . . . . . . . . . . . . . . . . . . . . Removing and installing flywheel, replacing gear ring 64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing crankshaft seal (flywheel end) 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exchanging bearing race 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft seals 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake / exhaust system Removing and installing intake manifold 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing exhaust manifold 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger, trouble shooting 72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the charge-air pressure 74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing turbocharger 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking axial and radial play of turbocharger rotor shaft 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exchanging waste gate 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing intercooler 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents 5 Cylinder head Removing and installing cylinder head 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting valve clearance 86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembling and assembling rocker arms 88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing valves 89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing valve guides 92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing valve seat insert 93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reworking valve seat 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refacing valves 98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking compression 99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve timing Removing and installing timing case 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing camshaft 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and fitting camshaft bearing bushes 103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking valve timing 112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankgear, pistons Removing and installing crankshaft 113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing piston with connecting rod 116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing piston from and attaching to connecting rod checking - changing connecting rod 119 . . . . . . Removing, installing and changing piston rings 121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing cylinder liners 123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring piston protrusion 126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attachments Removing and installing starter 127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-belts 128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant level probe 130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmitters 131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special tools 135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index 147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety instruction 6 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 circuit 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 circuit and downstream hydraulic oil circuit if fitted): risk of injuries resulting from emerging fluids. D When checking the injection nozzles, do not hold your hands in the fuel jet. Do not in- hale fuel mist.

Safety instruction 7 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”.

Safety instruction 8 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 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 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.

MAN D2866-LE D2876-LE Marine Diesel Engine Repair Manual

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