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Table of Contents
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Summary of Contents for Man D 2866 LE 201
- Page 3 Operating Instructions − MAN Industrial Diesel Engines...
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Page 5: Preface
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. -
Page 6: Instructions
Flat seals / gaskets can be fitted properly only if the following points are ob- served: 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... -
Page 7: Table Of Contents
Index Preface ..............Instructions . -
Page 8: Declaration
In accordance with Article 4, paragraph 2, in conjunction with Appendix II, section B, of Directive 89/392/EEC, version 93/44/EEC MAN Nutzfahrzeuge Aktiengesellschaft, hereby declares that the engine described below is destined for installation in a machine as defined in the EC directive on machines. -
Page 9: Nameplates
The engine type plates are on the crankcase. Model ..............delivered on ..............installed on ..............Engine serial number ..............Order number ..............MAN Nutzfahrzeuge Aktiengesellschaft Motor-Nr. / Engine No. NI/II MAN Nutzfahrzeuge Aktiengesellsc MAN Nutzfahrzeuge Aktiengesellschaft Werk Nürnberg Germany Bauj. Year Model Motor−Nr. Serial No Werk−Nr. -
Page 10: Safety Regulations
Ë Ë 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. - Page 11 Do not demand more from the engine than it is able to supply in its intended application. Detailed information on this can be found in the sales literature. The injection pump must not be adjusted without prior written permission of MAN Nürnberg.
- Page 12 If faults occur, find the cause immediately and have it eliminated in order to prevent more serious damage. Use only genuine MAN spare parts. MAN will accept no responsibility for damage result- ing from the installation of other parts which are supposedly “just as good”.
- Page 13 Safety regulations 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.
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Page 14: Commissioning And Operation
Commissioning and operation Engine views D 2866 LE 201 À Fan Æ Electro-hydraulic shut-off (EHAB) Á Oil filler neck Ç Fuel strainer  Air filter contamination gauge È Fuel lift pump à Air Cleaner É Injection pump Ä Crankcase breather Oil dipstick Å... - Page 15 Commissioning and operation Combustion air pipe to intercooler Alternator Combustion air pipe from intercooler Oil filter Water pump Turbocharger Tensioning pulley Starter motor...
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Page 16: First Commissioning
At the time of initial commissioning of a new or overhauled engine make sure to have observed the “Technical Information for the installation of MAN Diesel engines”. 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. -
Page 17: Commissioning
Commissioning and operation Commissioning Before daily starting the engine, check fuel level, coolant level and engine oil level and replenish, if necessary. Note: Use only approved fuels, lubricants etc. (see brochure “Fuels, lubricants etc.”). Otherwise the manufacturer’s warranty will become null and void. Checking oil level Check the oil level when the engine is horizontal, but only if at least 20 minutes have passed since the machine was switched off. -
Page 18: Starting
Commissioning and operation Starting Danger: Before starting make sure that no-one is in the engine’s danger area. Caution: When starting do not use any additional starting aids (e.g. injection with starting pilot). D Ensure that no load is on the engine before starting it, eg switch off load, disengage clutch, put gearbox into neutral etc. -
Page 19: Operation Monitoring System
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. -
Page 20: Maintenance And Care
Maintenance and care Lubrication system Ensure outmost cleanliness when handling fuels, lubricants and coolants. Note: Use only approved fuels, lubricants etc. (see brochure “Fuels, lubricants etc.”). Otherwise the manufacturer’s warranty 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. - Page 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 À.
- Page 22 Maintenance and care During continuous operation position the Continuous operation selector lever that both filter halves are in (both filter halves operation. in operation) Observe positions of selector lever! Right-hand filter Caution: cut out Do not leave selector lever in any intermediate position because this Left-hand filter would be liable to interfere with oil...
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Page 23: Fuel System
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 con- densation is prevented). - Page 24 Maintenance and care Parallel fuel filter (Single and parallel box-type filter) 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:...
- Page 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 dangerous waste and must be dis-...
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Page 26: Cooling System
Maintenance and care Cooling system Danger: Draining hot coolant involves a risk of scalding. Draining the cooling system Caution: Drain coolant into a suitable con- tainer and dispose of it in accor- dance with regulations. Drain coolant as follows, but only when the engine has cooled down: D Briefly open cap (large cap) on the filler neck of the expansion tank for pressure... - Page 27 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”. Coolant must be added at the filler neck only.
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Page 28: Air Filter
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 À Connection for contamination gauge Á Filter housing Â... - Page 29 Maintenance and care Contamination gauge À Red display cylinder Á Return knob In the window a red field appears which grows in size as the contamination in- creases. If the red field is fully visible in the window, the air filter is contaminated and must be Display: filter service is due cleaned or changed.
- Page 30 Maintenance and care Cleaning the cartridge Caution: The filter cartridge should normally be changed. Clean it only in emergencies (e.g. when no replacement 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.
- Page 31 Maintenance and care Safety cartridge When the main cartridge is being serviced the safety cartridge remains in the filter hous- ing. The engine must not be run without the main cartridge. Safety cartridges must be neither cleaned nor re-used. Safety cartridges must be changed: −...
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Page 32: Checking V-Belts
Maintenance and care Checking V-belts Checking condition D Check V-belts for cracks, oil, overheat- ing and wear D Change demaged V-belts Checking tension Use V-belt tension tester to check V-belt tension. D Lower indicator arm À into the scale D Apply tester to belt at a point midway between two pulleys so that edge of contact surface Á... - Page 33 Maintenance and care Tensioning and changing V-belt Water pump − Alternator D Remove fixing bolts À D Remove lock-nut Á D Adjust nut  until V-belts have correct tensions D Retighten lock-nut and fixing bolts To replace the V-belts loosen lock-nut and swing alternator inwards.
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Page 34: Turbocharger
Maintenance and care 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 overheat- ing of the engine. -
Page 35: Alternator
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 norm can be obtained from our After-Sales Service department, Nuremberg... -
Page 36: Technical Data
Technical data Model D 2866 LE 201 / 202 / 203 / 211 Design in-line vertical Cycle 4-stroke Diesel with turbocharger and in- tercooler Combustion system Direct injection Turbocharging Turbocharger with intercooler Number of cylinders Bore 128 mm Stroke 155 mm... - Page 37 Technical data Start of delivery ± 1° crank angle before TDC (Speed constant = without timing ad- justment) with optimised with optimised D 2866 LE 201 consumption 1500 1/min, constant 16° 8° 1800 1/min, constant 16° 12° D 2866 LE 202 1500 1/min, constant 16°...
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Page 38: Troubleshooting Table
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... - Page 39 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...
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Page 40: Index
Index Air filter ....... 28–31 Injection pump ......Alternator .
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