Operating Instructions

MAN Industrial Diesel Engines

D2866 E
D2866 TE
D2866 LE/LXE

51.99493-8263 “Translation of the original operating instructions”

Version 02
 Information and Copyright

Subject to technical alterations in the interests of further development.

The reprinting, reproduction or translation of this document, even in part, is not permitted without the
written permission of MAN. All rights under the law relating to copyright are expressly reserved by MAN.

 2014
MAN Truck & Bus AG
Vogelweiherstraße 33
90441 Nürnberg
Germany
Tel.: +49 911 / 420-0
Fax: +49 911 / 420-1939
Email: Engine-Dokumentation@man.eu
Internet: www.man-engines.com

Technical status: 10.2006

51.99493-8263

2
 Preface

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 book".

Note:
All three publications belong to the engine and must always be kept ready to hand near the en­
gine in the engine room.
Comply in full with instructions relating to operation, prevention of accidents and environmental
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.

Note:
Only use fuels, lubricants etc. in accordance with MAN's regulations.
Otherwise the manufacturer's liability for defects 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:
https://mmrepro.mn.man.de/bstwebapp/BSTServlet

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 repair work.

Yours faithfully,
MAN Truck & Bus AG
Werk Nürnberg

3
 Instructions

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:
Explanations useful for understanding the working or operating procedure to be performed.

4
 Contents

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Commissioning and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Engine views D 2866 E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
First commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Operation monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Shutting down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Temporary decommissioning of engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Troubleshooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5
 Nameplates

In all your correspondence please always quote

engine model, serial number and job number
(Order number).
For this reason it is advisable to read off the data
from the engine type plates before putting the en­
gine into operation and to enter them in the ap­
propriate spaces.
The engine type plates are on the crankcase
(see illustration).

Model .................................................................

delivered on .................................................................

installed on .................................................................

Engine serial number .................................................................

Order number .................................................................

MAN Nutzfahrzeuge Aktiengesellschaft

Typ
Motor-Nr. / Engine No.
NI/II

MAN Nutzfahrzeuge Aktiengesellschaft

Aktiengesellsc
Werk Nürnberg Germany
:

Bauj. Year Typ Model Motor−Nr. Serial No

Werk−Nr. Job No Leistung kW Rating kW Drehz. 1/min Speed rpm

Temp.C Leistg. PS Rating BHP Aufstellhohe m uNN Altitude m

:
:

−0219

6
 Safety regulations

General notes
Handling diesel engines and the necessary resources is no problem when the personnel commis­
sioned 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 sec­
tions which contain the information necessary for preventing injury to persons, 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 penetrat­
ing the skin, scalding from hot oil, anti-freeze being splashed in the eyes etc., consult a doctor immedi­
ately.

1. Regulations designed to prevent accidents with injury to persons

During commissioning, starting and operation

D Before putting the engine into operation for the first time, read the operating instructions
carefully and familiarize yourself with the “critical" points. If you are unsure, ask your
MAN representative.

D For 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.

D The engine must be started and operated only by authorized personnel.

Ensure that the engine cannot be started by unauthorized persons.
D When the engine is running, do not get too close to the rotating parts. Wear close-fitting
clothing.

D Do not touch the engine with bare hands when it is warm from operation - risk of burns.

ËË
D Exhaust gases are toxic. Comply with the instructions for the installation of MAN Diesel
engines which are to be operated in enclosed spaces. Ensure that there is adequate
ventilation and air extraction.
D Keep vicinity of engine, ladders and stairways free of oil and grease.
Accidents caused by slipping can have serious consequences.

7
 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.

Caution:

ËË
There is a risk of burns and scalding. Do not touch oil drain plugs or oil filters with bare
hands.

D Take into account the amount of oil in the sump. Use a vessel of sufficient size to
ensure that the oil will not overflow.
D Open the coolant circuit only when the engine has cooled down.

ËË
If opening while the engine is still warm is unavoidable, comply with the instructions in

ËË
the chapter entitled “Maintenance and Care".

D Neither 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.

D Fuel is inflammable. Do not smoke or use naked lights in its vicinity. The tank must be
filled only when the engine is switched off.

D When using compressed air, e.g. for cleaning the radiator, wear goggles.

D Keep service products (anti-freeze) only in containers which can not be confused with
drinks containers.

D Comply with the manufacturer's instructions when handling batteries.

Caution:
Accumulator acid is toxic and caustic. Battery gases are explosive.

8
 Safety regulations

2. 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 informa­
tion 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 resulting from the
installation of other parts which are supposedly “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. injection with starting pilot).
D Use only MAN-approved service products (fuel, engine oil, anti-freeze and anti-corrosion agent). Pay
attention to cleanliness. The Diesel fuel must be free of water. See “Maintenance and care".
D Have the engine maintained at the specified intervals.
D Do 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.
D Never put cold coolant into an overheated engine. See “Maintenance and care".
D Do 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.
D Always ensure that the testing and monitoring equipment (for battery charge, oil pressure, coolant tem­
perature) function satisfactorily.
D Comply with instructions for operation of the alternator. See “Maintenance and care".
D Do not let the seawater pump run dry. If there is a risk of frost, drain the pump when the engine is
switched off.

9
 Safety regulations

3. 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.
D Take strict precautions to ensure that no oil or Diesel fuel gets into the drains or the ground.
Caution:
The drinking water supply could be contaminated.
D Filter elements are classed as dangerous waste and must be treated as such.

Coolant
D Treat undiluted anti-corrosion agent and / or anti-freeze as dangerous waste.
D When disposing of spent coolant comply with the regulations of the relevant local authorities.

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,
irritation or inflammation of the skin may therefore occur. Used engine oil also contains dangerous sub­
stances which have caused skin cancer in animal experiments. 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:
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 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.
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. 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".

10
 Commissioning and operation

Engine views D 2866 E

1 2 3 4 5

9 8 7 6

13 12 11 10

11
 Commissioning and operation

(1) Tensioning pulley

(2) Coolant 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

12
 Commissioning and operation

Engine views D 2866 TE

3 4

5
2

9 8 7 6

13 12 11 10

13
 Commissioning and operation

(1) Tensioning pulley

(2) Coolant 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

14
 Commissioning and operation

Engine views D 2866 LE, LXE

1 2 3

7 6 5 4

14 13 12 11 10 9

15
 Commissioning and operation

(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) Coolant pump

(9) Tensioning pulley

(10) Oil filter

(11) Coolant drain plug

(12) Oil drain plug

(13) Turbocharger

(14) Starter motor

16
 Commissioning and operation

First commissioning
When putting a new or overhauled engine into operation for the first time pay attention to the “Installation
instructions for MAN marine diesel engines" without fail.
It is recommended that new or overhauled engines should not be operated at a load higher than about 75%
maximum load during the first few hours of operation. Initial run-in should be at varying speeds. After this
initial run-in, the engine should be brought up to full output gradually.

Caution:
Use only approved fuels, lubricants etc. (see brochure “Fuels, lubricants etc."). Otherwise the lia­
bility for defects will become null and void!

Filling with fuel

Caution:
Fill the tank only when the engine is switched off. Pay attention to cleanliness. Do not spill fuel.
Use only approved fuels (see “Fuels, Lubricants etc.").

Filling-in of coolant
Fill the cooling system of the engine with a mixture of drinkable tap water and anti-freeze agent on ethylene
glycole basis or anti-corrosion agent.
See Publication “Fuels, Lubricants and Coolants for MAN Diesel Engines".
D Pour in coolant slowly via expansion tank, see page 28
D For coolant filling quantity, see “Technical data"

Seawater pump
Do not let seawater pump run dry.
Make sure that all valves / cocks in the seawater circuit are open.
If there is a risk of frost, drain the seawater pump.

17
 Commissioning and operation

Filling with engine oil

Caution:
Do not add so much engine oil that the oil
level rises above the max. marking on the
dipstick. Overfilling will result in damage
to the engine.

The engines are as a rule supplied without oil.

Pour oil into engine via filler neck (arrow), see pa­
ge 22. For the quantity required see “Technical
Data".

Commissioning
Before daily starting the engine, check fuel level, coolant level and engine oil level and replenish, if neces­
sary.

Caution:
Use only approved fuels, lubricants etc. (see brochure “Fuels, lubricants etc."). Otherwise the lia­
bility for defects will become null and void!

Checking oil level

Oil

?
Check engine oil level only approx.
20 minutes after the unit has been switched off.
D Pull out dipstick
D wipe it with a clean, lintfree cloth
D and push it in again up to the stop
D Pull out dipstick again

MAX
MIN

The oil level should be between the two notches in the dipstick and must never fall below the lower notch.
Top up oil as necessary.

Caution:
Do not add so much engine oil that the oil level rises above the max. marking on the dipstick.
Overfilling will result in damage to the engine.

Ensure outmost cleanliness when handling fuels, lubricants and coolants.

18
 Commissioning and operation

Starting

Danger:
Before starting make sure that no-one is in the engine's danger area.

Ensure that the gearbox is in neutral.

Caution:
When starting do not use any additional starting aids (e.g. injection with starting pilot).

Insert starter key and turn it to position “I". The check lamp comes on to show that the engine is ready for
operation.
Turn starter key further to position “II" (pre-glow). The display lamp (usually in the driver's station) comes
on.
After the pre-glow period the display lamp begins to flash. This signalizes that the engine is ready for start­
ing.

Note:
If the engine is not equipped with a pre-glowing function, immediately turn the starter key through
to position “III".

Turn key further up to the stop (position “III"). The display lamp goes out. The starter motor is actuated.
Lube oil pressure must build up at the oil pressure gauge. If it does not, switch off the engine immediately.
For cold engines (<20C) move control lever into starting position (against stop for maximum engine
speed).

Note:
When starting the cold engine (control lever in starting position) retract the control lever as
quickly as possible into lower idling position after the engine has started.

The warm engine can also be started with the control lever in idling position.
Do not operate starter for longer than 10 seconds at a time.
After ignition of the engine, release the starter button and adjust control lever for desired speed.
If engine fails to start, release the key, wait about 30 seconds, then operate starter again.
For repeated starting turn the key back to OFF.
If the engine is kept idling for long periods it may cool down and thus start to emit white or blue smoke.
We therefore recommend that you do not let the engine idle for more than 5 minutes.
It is well known that with any internal combustion engine wear is higher during idling.
Idling for longer periods is also an environmental nuisance.

19
 Commissioning and operation

Operation monitoring system

Caution:
Do not overload the engine. Do not exceed the maximum permissible engine tilt.
If faults occur, find their cause immediately and have them eliminated in order to prevent more
serious damage!

During operation the oil pressure in the engine lubrication system must be monitored. If the monitoring
devices register a drop in the lube oil pressure, switch off the engine immediately.

Shutting down
After the engine has been running at a high load level, do not shut it down immediately but allow it to idle
about 5 minutes so that temperatures may equalize.
Set deck switch to “Neutral" and switch off the engine at the stop button / ignition key.
Remove key from starting lock.

Danger:
Ensure that the engine can not be started by unauthorized persons.

20
 Maintenance and care

Lubrication system
Ensure outmost cleanliness when handling fuels, lubricants and coolants.

Caution:
Use only approved fuels, lubricants etc. (see brochure “Fuels, lubricants etc."). Otherwise the lia­
bility for defects will become null and void!

Engine oil change

Danger:
The oil is hot- risk of scalding.
Do not touch the oil drain plug with bare
fingers.
Oil is an environmental hazard. Handle it
with care!

With the engine at operating temperature, remove

the oil drain plugs on the oil sump and the oil filter
bowl and allow the old oil to drain off completely.

Use a vessel of sufficient size to ensure that the oil

does not overflow.

As the oil drain plug is often not accessible, a

manually operated vane pump may be attached to
the engine for draining the oil.

Pump the old oil out of the sump while the engine
is still warm. Remove oil drain plugs in oil filter
bowl and let old oil drain out of oil filters.
Use a vessel of sufficient size to ensure that the oil
does not overflow.

Refit the oil drain plugs with new gaskets.

Note:
Change the oil filter elements every time
the engine oil is changed.

21
 Maintenance and care

Refilling with oil

Caution:
Do not add so much engine oil that the oil
level rises above the max. marking on the
dipstick. Overfilling will result in damage
to the engine.

Refill with fresh engine oil at the oil filler neck

(arrow).
After filling start the engine and let it run for a few
minutes at low speed.

Caution:
If no oil pressure builds up after approx.
10 seconds switch off the engine immedi­
ately.

Check oil pressure and check that there is no oil

leakage. Oil
Then shut down the engine. After about
20 minutes, check the oil level.
D Pull out dipstick
?
D wipe it with a clean, lintfree cloth
D and push it in again up to the stop
D Pull out dipstick again
The oil level should be between the two notches in MAX
the dipstick and must never fall below the lower
notch. Top up oil as necessary.
MIN

Changing oil filter

A changeover-type oil filter, the filter elements of
which can be replaced even during operation, can
be fitted on request.
However, oil filter cartridges must be changed at
every oil change.

22
 Maintenance and care

During continuous operation position the selector

lever that both filter halves are in operation. Continuous operation (both
Observe positions of selector lever! filter halves
in operation)
Caution:
Do not leave selector lever in any inter­ Right-hand filter
mediate position because this would be cut out
liable to interfere with oil supply. If in
doubt stop engine to change oil filter.

Left-hand filter
Renewal of filter cartridges cut out
D Allow the filter content to run off along drain
plugs (1).
Hold a suitable vessel under hole
2 3
Danger:
The oil is hot and under pressure when
the drain plug is opened.
Risk of burns and scalds.

D After releasing the clamping bolts (3) remove

filter bowls (2)
D Renew filter cartridges (4). Thoroughly clean all
other parts in cleaning fluid (do not allow clean­
ing fluid to enter the oil circuit)
D Use new gaskets (5) for reassembly of filter 1 4 5
bowls

Note:
To prevent the seal (5) from twisting hold
the filter bowl (2) firmly when tightening
the tensioning screw (3).

Caution:
Used oil filters are classed as dangerous
waste and must be disposed of
accordingly.

1
3

23
 Maintenance and care

Fuel system

Fuel
If Diesel fuel which contains moisture is used the injection system and the cylinder liners / pistons will be
damaged. This can be prevented to same extent by filling the tank as soon as the engine is switched off
while the fuel tank is still warm (formation of condensation is prevented). Drain moisture from storage tanks
regularly. Installation of a water trap upstream of the fuel filter is also advisable. Do not use any additives to
improve flow properties in winter.

Caution:
Use only approved fuels, lubricants etc. (see brochure “Fuels, lubricants etc."). Otherwise the lia­
bility for defects will become null and void!

Injection pump
Neither the injection pump nor the control unit must be modified in any way. If the lead seal is damaged the
engine warranty will become null and void.

Faults
We urgently recommend that you have faults in the injection pump rectified only in an authorized specialist
workshop.

Cleaning fuel pre-cleaner

Strip the fuel pre-cleaner (1):
D Unscrew knurled nut of pre-cleaner
D Swing out retaining arm and take out filter
3
housing (3) with strainer filter (2)
D Wash out filter housing and strainer filter in
clean Diesel fuel and blow dry with compressed 1
air
2
D Re-assemble in reserve order

D Actuate tappet of hand primer until overflow

valve of injection pump is heard to open
D Screw in the tappet of the hand pump again
and tighten it
D Start engine
D Check fuel pre-cleaner for leaks

24
 Maintenance and care

Parallel fuel filter

Draining moisture:
Unscrew drain plugs at every oil change until mois­
ture has been discharged and clean fuel flows out.

Changing fuel filter

Only when engine is switched off
D Loosen filter with tape wrench and remove it
D Wet seal on new filter with fuel
D Screw on filter by hand
D After this, bleed the fuel system
D Check filter for leaks

Caution:
Used fuel filters are classed as danger­
ous waste and must be disposed of
accordingly.

Change-over fuel filter

Continuous operation (both
Where the changeover-type filter is installed, the filter halves
servicing procedure is for the filter side requiring to in operation)
be shut off with the engine running. During continu­
ous operation, the selector lever should be placed
in a position where both filter halves are in oper­ Right-hand filter
ation. cut out

Caution:
Do not leave selector lever in any inter­ Left-hand filter
mediate position because this would be cut out
liable to interfere with fuel supply. If in
doubt stop the engine to change the fuel
filter.

25
 Maintenance and care

Changing fuel filter

D Loosen filter with tape wrench and remove it
D Wet seal on new filter with fuel
D Screw on filter by hand
D After this, bleed the fuel system
D Check filter for leaks

Caution:
Used fuel filters are classed as danger­
ous waste and must be disposed of
accordingly.

Bleeding the fuel system

An arrow on the filter head indicates the direction
of fuel flow.
D Unscrew bleed screw of first filter in direction of
flow by one or two turns
D Actuate tappet of hand primer until fuel
emerges without bubbles
D Screw in the tappet of the hand pump again
and tighten it
D Close bleed screw again
D Repeat this procedure at the second bleed
screw
D Check filter for leaks

26
 Maintenance and care

Cooling system

Danger:
Draining hot coolant involves a risk of scalding.

Draining the cooling system

1
Caution:
Drain coolant into a suitable container
and dispose of it in accordance with
regulations.

Drain coolant as follows, but only when the en­

gine has cooled down.

D Briefly open cap ((1), large cap) on the filler

neck of the expansion tank for pressure com­
pensation

D Remove drain plug in crankcase, oil cooler

housing and exhaust manifold

D Then remove cap (1)

D Drain coolant into a container of adequate size

D Refit screw plugs

D Filling / bleeding the cooling system

Drain plug in oil cooler housing

Drain plug in oil cooler housing cover

27
 Maintenance and care

Filling / bleeding the cooling system (only when engine has cooled down)
Fill the cooling system of the engine with a mixture of drinkable tap water and anti-freeze agent on ethylene
glycole basis or anti-corrosion agent.

Caution:
Use only approved fuels, lubricants etc. (see brochure “Fuels, lubricants etc."). Otherwise the lia­
bility for defects will become null and void!

Coolant must be added at the filler neck only ((1), large cap). When topping up do not add cold coolant
if the engine is still warm from operation.
Ensure that the ratio of water to anti-freeze is correct.
Find the cause of the loss of coolant and have it eliminated.

D Remove cap ((1), large cap)

D Slowly fill up with coolant until correct coolant
1
level is reached
D Make sure that all air can escape from the cool­
ing system
D Run the engine briefly and then check coolant
level once more

Danger:
If, in an exceptional case, the coolant level has to be checked in an engine that has reached
operating temperature, first carefully turn the cap ((1), large cap) with safety valve to the first stop,
let off pressure, then open carefully.

Caution:
If the cap with the working valves is opened, there is the risk that it will not close tightly again af­
terwards. The excess pressure required in the system will then no longer build up. Premature boil­
ing occurs and coolant is lost. To prevent damage to the engine open this cap only in exceptional
circumstances and fit a new one as soon as possible.

28
 Maintenance and care

Air filter

Fitted: Duralite air filter

Note:
Do not service or wash out the filter.

The filter must be changed after every 200 hours

of operation.

Fitted: Piclon air filter

(1) Connection for contamination gauge 1 2 3 4 5 6 7
(2) Filter housing
(3) Retainer
(4) Filter cartridge
(5) Hex nut
(6) Lid
(7) Dust collector
Service only when engine is switched off.

Dust collector
The dust collector must be emptied at regular in­
tervals. The collector should never be more than
half full of dust.
When the two retainers have been folded up the
dust collector can be taken off.
Remove the lid of the dust collector and empty the
collector.
Ensure that the lid and the collector are reas­
sembled correctly. A lug on the collector fits into a
recess in the edge of the lid. If the filter is installed
horizontally note the “oben" (“top") marking on the
filter bowl.

29
 Maintenance and care

Contamination gauge
1 2
(1) Red display cylinder
(2) Return knob

In the window a red field appears which grows in

size as the contamination increases.

If the red field is fully visible in the window, the air

filter is contaminated and must be cleaned or
changed.

Display: filter service is due

When the filter has been changed pull the return
knob. The red field then disappears.

Display: filter is ready for operation

Changing the filter cartridge

Caution:
No dust must get to the clear air end.

Remove the hex hut, take out the contaminated

cartridge and fit a new one.
Clean the filter housing with a damp cloth, es­
pecially at the sealing face for the cartridge.

Caution:
The engine must not be run without a
main cartridge.

30
 Maintenance and care

Cleaning the cartridge

Caution:
The filter cartridge should normally be changed. Clean it only in emergencies (e.g. when no re­
placement is available).

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 cartridge.
Blow the cartridge out from the inside with dry
compressed air (max. 5 bar) by moving the pipe up
and down inside the cartridge until no more dust is
released.

Checking the cartridge

When a cartridge has been cleaned it must be
examined for damage before it is refitted, e.g.
damage to the paper bag and rubber seals. Check
also for compression of or dents in the metal
jacket.
Tears and holes in the paper bag can be found by
shining a torch into the bag.
On no account re-use damaged cartridges. If in
doubt fit a new cartridge.

31
 Maintenance and care

Safety cartridge
When the main cartridge is being serviced the safety cartridge remains in the filter housing. The engine
must not be run without the main cartridge.
Safety cartridges must be neither cleaned nor re-used.

Safety cartridges must be changed:

- at the latest after being in use for two years
- if, after the main cartridge has been serviced
(changed), the contamination gauge responds
again immediately
- if the main cartridge is defective
When the main cartridge has been removed the
safety cartridge is accessible and can be removed
also.
Remove the hex nut.
Pull out the safety cartridge.
Insert a new safety cartridge. Refit and tighten the
hex nut.

Viscous air cleaner

As soon as a distinct layer of dust has accumu­

lated on the filter element, remove air cleaner and
wash in fuel or cleaning oil.
Shake element out thoroughly to dry it.
Uniformly coat filter surface with a thin film of en­
gine oil.

32
 Maintenance and care

V-belts

Checking condition
1
If, in the case of a multiple belt drive, wear or dif­
fering tensions are found, always replace the com­
plete set of belts.
D Check V-belts for cracks, oil, overheating and
wear
D Change demaged V-belts

Checking tension
Use V-belt tension tester to check V-belt tension. 2
D Lower indicator arm (1) into the scale
D Apply tester to belt at a point midway between
two pulleys so that edge of contact surface (3)
is flush with the V-belt
D Slowly depress pad (2) until the spring can be
heard to disengage. This will cause the indica­
tor to move upwards
If pressure is maintained after the spring has dis­
engaged a false reading will be obtained! 3

Reading of tension Tensioning forces according to the

kg graduation on the tester
D Read of the tensioning force of the belt at the
point where the top surface of the indicator arm Drive belt New installation When
(1) intersects with the scale width servicing
D Before taking readings make ensure that the After 10 after long
Installation min. run­ running
indicator arm remains in its position ning time time
If the value measured deviates from the setting
9.5 45-50 40-45 30
value specified, the V-belt tension must be cor­
rected. 10.0 45-50 35-40 30
12.5 50-55 45-50 35
13.0 50-55 40-45 35
20.0 75 70 60
22.0 75 70 60
2/3VX 90-100 70-80 60
3/3VX 135-150 105-120 90

33
 Maintenance and care

Tensioning and changing V-belt

D Remove fixing bolts (1)

D Remove lock-nut (2)
D Adjust nut (3) until V-belts have correct
tensions 3
D Retighten lock-nut and fixing bolts
1
2
To replace the V-belts loosen lock-nut and swing
1 2
alternator inwards.

Turbocharger
At every engine oil change check the oil pipes for leaks and constrictions.
Furthermore, a regular check should be kept on charge air and exhaust gas pipes.
Any leakages should be attended to at once because they are liable to cause overheating of the engine.

Intercooler
If the coolant output is to be retained as far as possible, the intercooler must be cleaned at certain intervals.

Starter motor
Check that the electric cables are properly fastened and that contacts and plug connections are secure.

Note:
Always disconnect the battery earth cable before starting work on the electrical system. Connect
up the earth cable last, as there is otherwise a risk of short-circuits.

34
 Maintenance and care

Alternator
The alternator is maintenance-free.
Nevertheless, it must be protected against dust and, above all, against moisture.
In order to avoid damage to the alternator, observe the following instructions:

While the engine is running

D Do not de-energize the main battery switch!
D Do not disconnect the battery or pole terminals or the cables!
D If, during operation, the battery charge lamp suddenly lights up, stop the engine immediately and rem­
edy the fault in the electrical system!
D Do not run the engine unless the battery charge control is in satisfactory order!
D Do not short-circuit the connections of the alternator with those of the regulator or said connections with
ground, not even by briefly bringing the connections into contact!
D Do not operate the alternator without battery connection!

Temporary decommissioning of engines

Temporary anti-corrosion protection according to MAN works norm M 3069 is required for engines which
are to be put out of service for fairly long periods.
The works standard can be obtained from our After-Sales Service department in Nuremberg.

35
 Notes

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36
 Technical data

Model D 2866 E
Design in-line vertical
Cycle 4-stroke Diesel
Combustion system Direct injection
Number of cylinders 6
Bore 128 mm
Stroke 155 mm
Swept volume 11 967 cm3
Compression ratio 17.5 : 1
Rating see engine nameplate
Firing order 1-5-3-6-2-4
Valve clearance (cold engine)
Intake 0.25 mm
Exhaust 0.40 mm
Valve timing
Intake opens 11 before 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 centrifugal type in camshaft drive gear
Injectors 4-orifice nozzles
Opening pressure of injector
New nozzle holder: 265 + 8 bar
Used nozzle holder: 250 + 8 bar
Start of delivery  1 crank angle before TDC (Speed constant = without timing adjustment)
1500 rpm, constant 22
1800 rpm, constant 24
1500 rpm, variable 17
1800 rpm, variable 17
2100 rpm, variable 17
2200 rpm, variable 17

37
 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 change quantity (with filter)
Deep 21 l
Shallow 23 l
For 30 tilt 21 l
Oil pressure during operation (depending on oil must be monitored by oil pressure
temperature, oil viscosity class and monitors/gauges
engine rpm)
Oil filter Full flow filter with two paper cartridges
Engine cooling system Liquid cooling
Coolant temperature 80-85C, temporarily 90C allowed
Coolant filling quantity 58 l
Electrical equipment
Starter 24 V; 5.4 kW or 6.5 kW
Alternator 28 V; 35, 55 or 120 A

38
 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 6
Bore 128 mm
Stroke 155 mm
Swept volume 11 967 cm3
Compression ratio 15.5 : 1
Rating see engine nameplate
Firing order 1-5-3-6-2-4
Valve clearance (cold engine)
Intake 0.50 mm
Exhaust 0.50 mm
Valve 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 type
Injection timer Automatic centrifugal type in camshaft drive gear
Injectors 4-orifice nozzles
Opening pressure of injector
New nozzle holder: 220 + 8 bar
Used nozzle holder: 220 + 8 bar
Start of delivery  1 crank angle before TDC (Speed constant = without timing adjustment)
1500 rpm, constant 24
1800 rpm, constant 26
1800 rpm, variable 19
2100 rpm, variable 19
2200 rpm, variable 19

39
 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 change quantity (with filter)
Deep 21 l
Shallow 23 l
For 30 tilt 21 l
Oil pressure during operation (depending on oil must be monitored by oil pressure monitors/gau­
temperature, oil viscosity class and engine ges
rpm)
Oil filter Full flow filter with two paper cartridges
Engine cooling system Liquid cooling
Coolant temperature 80-85C, temporarily 90C allowed
Coolant filling quantity 58 l
Electrical equipment
Starter 24 V; 5.4 kW or 6.5 kW
Alternator 28 V; 35, 55 or 120 A

40
 Technical data

Model D 2866 LE, LXE

Design in-line vertical
Cycle 4-stroke Diesel with turbocharger and intercooler
Combustion system Direct injection
Turbocharging Turbocharger with intercooler
Number of cylinders 6
Bore 128 mm
Stroke 155 mm
Swept volume 11 967 cm3
Compression ratio
D 2866 LE 15.5 : 1
D 2866 LXE 16 : 1
Rating see engine nameplate
Firing order 1-5-3-6-2-4
Valve clearance (cold engine)
Intake 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 0.50 mm
Exhaust 0.50 mm
See instruction label on valve cover
Valve timing D 2866 LE
Intake opens 23 before TDC
Intake closes 37 after BDC
Exhaust opens 60 before BDC
Exhaust closes 30 after TDC
Valve timing D 2866 LXE
Intake opens 23 before TDC
Intake closes 12 after BDC
Exhaust opens 60 before BDC
Exhaust closes 30 after TDC
Fuel system
Injection In-line pump, with flange fastening
Governor All speed type
Injection timer Automatic centrifugal type in camshaft drive gear

41
 Technical data

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 280 + 8 bar
Start of delivery  1 crank angle before TDC Injection pump Exhaust manifold
(Speed constant = without timing adjustment) dry liquid-cooled
1500 rpm, constant 23 20
1500 rpm, constant (LXE) 15 -
1800 rpm, constant 25 22
1800 rpm, constant (LXE) 16 -
1800 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 51.11103-7072 - 21
2200 rpm, variable (LXE) 51.11102-7993 - 15
2200 rpm, variable (LXE) 51.11103-7071 - 21
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 change quantity (with filter)
Deep 21 l
Shallow 23 l
For 30 tilt 21 l
Oil pressure during operation (depending on oil must be monitored by oil pressure monitors/gau­
temperature, oil viscosity class and engine ges
rpm)
Oil filter Full flow filter with two paper cartridges
Engine cooling system Liquid cooling
Coolant temperature 80-85C, temporarily 90C allowed
Coolant filling quantity 58 l
Electrical equipment
Starter 24 V; 5.4 kW or 6.5 kW
Alternator 28 V; 35, 55 or 120 A

42
 Troubleshooting table

Fault
Engine does not start, or starts only with difficulty
Engine starts but does not reach full speed or stalls
Engine idles out of true when warm, misfiring
Engine speed fluctuates during operation
Power output unsatisfactory
Coolant temperature too high, coolant being lost
Lube oil pressure too low
Lube oil pressure too high
Black smoke accompanied by loss of power
Blue smoke
White smoke
Knocking in the engine
Engine “too loud"
Reason
D Fuel tank empty
D Fuel cock closed
D D D D D Air in fuel system
D D D D D Fuel pre-filter / pre-cleaner clogged
D Condensation in fuel
D D D D Air filter clogged
D Electric circuit interrupted
D Batteries flat
D Starter / solenoid switch defective
D D D D D Start of delivery not correct / incorrectly set
D Injection nozzles clogged
D Internal damage to engine
(piston seized, possibly caused by water in fuel)
D D D Fuel quality not in accordance with specifications or fueled severely
contaminated
D Lower idling speed set too low
D D D D Valve clearance incorrect
D Injection nozzles of injection pipes leaking
D Too little fuel in tank
D Rev. counter defective
D D D Injection nozzles defective or carbonized
D Engine being asked to do more than it has to
D Fuel supply faulty, fuel too warm
D D Oil level in sump too high
D Incorrect rated speed setting
D Coolant level too low
D Air in coolant circuit
D Radiator very dirty
D Tension of coolant-pump V-belts incorrect (slip)
D Cap with working valves on expansion tank / radiator defective or
leaking
D Temperature gauge defective

43
 Troubleshooting table

Fault
Engine does not start, or starts only with difficulty
Engine starts but does not reach full speed or stalls
Engine idles out of true when warm, misfiring
Engine speed fluctuates during operation
Power output unsatisfactory
Coolant temperature too high, coolant being lost
Lube oil pressure too low
Lube oil pressure too high
Black smoke accompanied by loss of power
Blue smoke
White smoke
Knocking in the engine
Engine “too loud"
Reason
D Coolant pipes leaking, blocked or twisted
D Oil level in sump too low
D Engine temperature too high
D Oil filter clogged
D D Oil pressure gauge defective
D D Selected oil viscosity not suitable for ambient temperature (oil too thin)
D Oil in sump too thin (mixed with condensation or fuel)
D Engine cold
D D Engine, coolant or intake air still to cold
D Lube oil getting into combustion chamber
(piston worn, piston rings worn or broken)
D Overpressure in crankcase (crankcase breather clogged)
D long operation under a low load
D Coolant getting into combustion chamber
(cylinder head / gasket leaking)
D Engine operating temperature incorrect
D Intake or exhaust pipe leaking

44
 Index

A R
Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 - 32 Refilling with oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
S
B Safety regulations . . . . . . . . . . . . . . . . . . . . . . 7 - 11
Bleeding the fuel system . . . . . . . . . . . . . . . . . . . 26 Handling used engine oil . . . . . . . . . . . . . . . . . . 10
Preventing accidents with injury to persons . . . 7
C Preventing damage to engine and premature
Changing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . 22 wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Preventing environmental damage . . . . . . . . . 10
Cleaning fuel pre-cleaner . . . . . . . . . . . . . . . . . . . 24 Seawater pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Shutting down . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Commissioning and operation . . . . . . . . . . . 11 - 20 Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Cooling system . . . . . . . . . . . . . . . . . . . . . . . 27 - 28 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 - 20

D T
Draining the cooling system . . . . . . . . . . . . . . . . . 27 Technical data . . . . . . . . . . . . . . . . . . . . . . . . 37 - 42
Temporary decommissioning . . . . . . . . . . . . . . . . 35
E
Troubleshooting table . . . . . . . . . . . . . . . . . . 43 - 44
Engine oil change . . . . . . . . . . . . . . . . . . . . . . . . . 21
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Engine views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
V
F
V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 - 34
Filling / bleeding the cooling system . . . . . . . . . . 28
Filling with engine oil . . . . . . . . . . . . . . . . . . . . . . . 18
Filling with fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Filling-in of coolant . . . . . . . . . . . . . . . . . . . . . . . . 17
First commissioning . . . . . . . . . . . . . . . . . . . 17 - 18
Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Changing fuel filter . . . . . . . . . . . . . . . . . . . . 25, 26
Draining moisture . . . . . . . . . . . . . . . . . . . . . . . . 25
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . 24 - 26

I
Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

L
Lubrication system . . . . . . . . . . . . . . . . . . . . 21 - 23

M
Maintenance and care . . . . . . . . . . . . . . . . . 21 - 35

N
Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

O
Operation monitoring system . . . . . . . . . . . . 20 - 22

45
MAN Truck & Bus AG
Vogelweiherstraße 33
90441 Nürnberg
Germany

A member of the MAN Group

Printed in Germany 51.99493-8263