Man D 2866 LUE 605 - User Manual

Guidance on correctly fitting flat seals and gaskets to ensure proper sealing and prevent leaks.

Instructions for the correct fitting of toric seals, including preparation and installation steps.

Overview of important instructions for preventing accidents, protecting persons, and minimizing engine damage.

Detailed guidelines and precautions to prevent personal injury during maintenance and repair work.

Essential practices for engine maintenance and repair to avoid damage and ensure longevity.

Guidelines for safe handling and disposal of oils, filters, and coolants to protect the environment.

Safety and hygiene regulations for handling used engine oil and its proper disposal.

The critical importance of pressurizing internal combustion engines with lube oil before recommissioning to prevent bearing damage.

Details the process and advantages of engine pressurization, including oil quantity and connection points.

Introduction to identifying and rectifying operating faults by determining causes and implementing repairs effectively.

Addresses problems related to engine starting, including slow cranking, no start, and difficulty starting when cold or hot.

Covers symptoms like stalling, lack of full revs, idle speed problems, reduced output, and irregular operation.

Discusses excessive smoke (white, blue, black) and engine overheating issues, including coolant loss.

Details problems related to high fuel consumption and issues with lubricating oil pressure and consumption.

Covers potential issues within the fuel low and high-pressure systems, including leaks, air, and component failures.

Addresses problems related to the Electronic Diesel Control (EDC) system, sensors, and control unit.

Discusses problems related to coolant level, V-belt tension, water pump, and thermostat faults.

Details potential faults within the EDC control unit itself and related programming or voltage issues.

Visual identification of key engine parts through diagrams and numbered labels for easy reference.

A detailed list of engine components identified in the diagrams, including Injection pump, Turbocharger, etc.

Schematic representation of the engine lubrication system, illustrating oil flow and component connections.

Diagram showing the fuel system layout for the D 2866 LUE 602 model, including key components.

Diagram illustrating the fuel system configuration for the D 2866 LUE 605 model.

Diagram of the engine cooling system, detailing the arrangement of components like radiator, thermostat, and water pump.

Illustrates the gear arrangement for engine timing and management, showing crankshaft, camshaft, and idler gears.

Outlines methods for checking the injection pump's start-of-delivery setting using scales, pointers, and visual indicators.

Describes using a light signal transmitter to precisely determine the injection pump's start-of-delivery point.

Details an alternative method for setting the start of delivery using a precision plug-in sleeve.

Step-by-step instructions for adjusting the injection pump's start-of-delivery if it is found to be incorrect.

Procedures for safely removing the injection pump, including disconnecting lines and fuel connections.

Steps for installing the injection pump, covering flange preparation, O-ring replacement, and initial tightening.

Detailed steps for removing injection nozzles, including line disconnection and extraction.

Guidance on installing new fuel injectors, including sealing rings and correct tightening procedures.

Methods for checking injector opening pressure, tightness, and spray pattern using a nozzle tester.

Procedures for safely disassembling fuel injectors for inspection and cleaning.

Steps for cleaning internal parts, checking for wear, and replacing components as needed.

Instructions for cleaning the fuel pre-filter specific to the D 2866 LUE 602 engine model.

Steps for cleaning the fuel pre-filter for the D 2866 LUE 605 engine model.

Procedure for bleeding air from the fuel system after changing the fuel filter to ensure proper operation.

Instructions for the removal of the sheathed-element glow plug, including electrical and fuel line disconnection.

Steps for installing the sheathed-element glow plug, ensuring correct alignment and connection.

Instructions for safely draining coolant from the system, emphasizing cooling down and proper disposal.

Procedures for filling and bleeding the cooling system with the correct coolant mixture.

Method for testing thermostat operation by immersing it in water and checking its opening temperature and stroke.

Steps for removing the engine water pump, including draining coolant and V-belt removal.

Procedures for installing the engine water pump, involving new seals, O-rings, and correct bolt tightening.

Detailed steps for disassembling the water pump, including pulley removal and circlip extraction.

Instructions for assembling the water pump, focusing on bearing installation, shaft fitting, and seal placement.

Specifics on the coolant pump design for engines with three thermostats, including component identification.

Steps for disassembling the coolant pump, covering cover removal, impeller extraction, and shaft separation.

Procedures for reassembling the coolant pump, including bearing installation, seal fitting, and housing assembly.

Further steps in coolant pump reassembly, focusing on mechanical seal installation and housing alignment.

Final steps for coolant pump reassembly, including impeller pressing and cover fitting.

Method for cleaning external radiator deposits to ensure sufficient cooling efficiency.

Procedure for cleaning the internal cooling system to prevent water pump seal damage from poor coolant condition.

Steps for removing lime deposits from the cooling system using specific pickling fluids.

Information on the aging of rubber gaskets in filler caps and working valves and their replacement.

Guidelines for treating and disposing of waste cleaning and pickling fluids.

Steps for changing the oil filter, including draining oil, removing the filter cup, and installing a new cartridge.

Procedures for removing the oil cooler, including draining oil and disconnecting mounting bolts.

Steps for installing the oil cooler, ensuring correct O-ring placement and bolt tightening.

Steps for removing the engine oil pan, including draining oil and disconnecting various components.

Procedures for fitting the oil pan, including gasket replacement and correct bolt tightening.

Steps for removing the oil pump, including oil pan removal and suction pipe disconnection.

Procedures for repairing the oil pump, focusing on cover removal, gear inspection, and drive gear installation.

Method for checking the axial clearance of the oil pump wheels using a dial gauge.

Instructions for removing the oil spray nozzle, including valve disconnection and removal.

Steps for removing the pilot clutch, including bolt removal and propshaft disconnection.

Procedure for removing the vibration damper, involving engine positioning, V-belt removal, and screw loosening.

Instructions for replacing the front crankshaft gasket and radial shaft sealing ring.

Steps for removing and installing the bearing race using specialized tools.

Guidance on installing the radial shaft sealing ring, emphasizing the use of transport sleeves.

Instructions for positioning and tightening the vibration damper and its associated components.

Steps for fitting the pilot clutch, including cleaning parts, connecting propshaft, and torque specifications.

Procedures for removing the flywheel, including releasing mounting bolts and using lifting gear.

Steps for fitting the flywheel, including guide pin insertion and bolt tightening.

Instructions for removing and replacing the starter gear ring, including heating and pressing.

Steps for removing the crankshaft seal using special tools or a screwdriver.

Procedures for installing a new crankshaft seal, including bearing race replacement and mandrel use.

Detailed steps for exchanging the bearing race, involving flywheel removal, heating, and pressing.

Information on PTFE seals, their characteristics, and handling precautions.

Critical assembly instructions for PTFE crankshaft seals, emphasizing cleanliness and proper installation.

Steps for removing the intake manifold, including electrical cable and fuel pipe disconnection.

Procedures for installing the intake manifold, ensuring correct gasket seating and bolt tightening.

Instructions for removing the exhaust manifold, noting its weight and the use of stud bolts as guides.

Steps for installing the exhaust manifold, including the use of stud bolts, gaskets, and specified torques.

Essential checks to perform before replacing a turbocharger to diagnose issues like oil consumption and power loss.

Troubleshooting steps for excessive oil consumption, including air filter checks and intake line inspection.

Common causes of unsatisfactory engine power, including fuel delivery, valve clearance, and compression issues.

Troubleshooting steps for abnormal engine noise related to the turbocharger and charge group.

Addresses oil accumulation in charge-air systems, potential causes, and corrective actions.

Requirements for accurate charge-air pressure measurement, including engine settings and temperature.

Specific instructions for measuring boost pressure downstream of the intercooler at rated engine speed.

Detailed steps for removing the turbocharger, including detaching pipes and guard plates.

Procedures for installing the turbocharger, emphasizing reverse order, new gaskets, and oil supply line filling.

Method for measuring the axial clearance of the turbocharger rotor shaft using a dial gauge.

Procedure for measuring the radial clearance of the turbocharger's turbine wheel with a dial gauge.

Steps for removing rocker arms and push rods before cylinder head removal, including cover removal.

Procedures for removing the cylinder head, including draining coolant and manifold detachment.

Steps for installing the cylinder head, covering cleaning, gasket placement, and bolt tightening.

Procedure for installing rocker arms and push rods, including checking for distortion and proper alignment.

Important notes regarding the sealing effect of cylinder head gaskets and the use of calibrated torque wrenches.

Instructions for adjusting valve clearance when the engine is cold, including cylinder identification and synchronous cylinder settings.

Steps for removing the rocker arm mechanism, including disengaging securing rings.

Guidance on fitting rocker arms onto rocker shafts, emphasizing lubrication of sliding surfaces.

Detailed steps for removing valves, including spring plate, springs, and valve stem seals.

Procedures for installing valves, including spring washers, springs, and valve cone pieces.

Method for measuring valve recess using a dial gauge to ensure correct seating.

Instructions for pressing out and installing valve guides using specialized mandrels.

Information on valve guide lengths and the necessity of reworking valve seats after guide replacement.

Methods for removing valve seat inserts using machining tools or welding techniques.

Procedures for installing new valve seat inserts, including cooling and pressing methods.

Detailed steps for reworking valve seats using a precision valve seat machining device.

Guidance on the valve seat machining process, including tool settings and ensuring correct seat angle.

Procedures for machining cylinder head interfaces and reworking seat inserts to achieve correct valve protrusion.

Instructions for refacing valve seats using a valve refacer, ensuring a faultless grinding pattern.

Explains the importance of correct valve seat width for preventing leaks and valve burning.

Steps for checking engine compression pressure using a compression recorder and comparing values.

Procedures for removing the gear case, including pipe removal and bolt release.

Steps for fitting the gear case, including gasket placement, flywheel housing fitting, and bolt tightening.

Instructions for removing the camshaft, emphasizing turning the engine and avoiding damage to bearings.

Procedures for driving out old and driving in new camshaft bearing bushings.

Steps for fitting the camshaft, including oiling valve tappets, bearings, and the camshaft itself.

Steps for checking valve timing, including setting valve clearance and using a dial gauge for stroke measurement.

Detailed procedure for removing the crankshaft, including conrod removal and bearing cap release.

Method for measuring and checking the spread of bearing bushes for proper fit.

Procedures for installing the crankshaft, covering cleaning, bearing insertion, and final tightening.

How to measure crankshaft axial clearance using a dial gauge and thrust bearing.

Steps for removing pistons and connecting rods, including bearing cover removal and piston pin extraction.

Procedures for installing pistons and connecting rods, covering bearing bush fitting and piston ring adjustment.

Final steps for piston installation, including conrod bearing cap fitting and engine turning.

Instructions for removing pistons from conrods, including piston pin fastening and piston removal.

Method for measuring the conrod foot bore to check for wear and ensure proper bearing fit.

Visual inspection of the conrod for damage and checks for parallel location and twisting.

Illustration of the correct arrangement of piston rings on the piston.

Steps for removing piston rings using specialized pliers, including cleaning the grooves.

How to measure piston ring end clearance using a feeler gauge and checking wear limits.

Procedure for checking piston ring axial clearance in each groove.

Detailed steps for removing cylinder liners using specialized extraction tools.

Method for measuring cylinder liner protrusion using a dial gauge and checking for correct seating.

Procedures for installing new cylinder liners, including O-ring placement and protrusion measurement.

Steps for measuring piston protrusion using a dial gauge after removing cylinder heads.

Instructions for disconnecting electrical cables and removing the starter motor.

Reference to page 73 for replacing the starter motor toothed ring.

Guidelines for checking V-belts for damage like cracks, oil, overheating, and wear.

Methods for checking V-belt tension using a V-belt tension tester and reading the scale.

How to read the tensioning force from the indicator arm and correct tension if values deviate.

Instructions for dismantling the pilot clutch into its individual parts.

Procedures for cleaning clutch parts, specifying suitable cleaning agents and methods for different contamination levels.

General guidelines for examining and maintaining the pilot clutch, including wear limits and spare parts.

Table detailing wear limits for friction disks and rings, indicating when replacement is advisable.

Explains how to measure friction ring wear and the procedure for determining relative movement.

Steps for assembling the pilot clutch, emphasizing bolt tightening torques and part placement.

Key specifications for the engine, including design, mode of operation, cylinders, bore, stroke, and capacity.

Lubrication details, including oil capacity in the sump and oil change quantity.

Data related to the engine's cooling system, including fluid type and coolant temperature.

Technical data and dimensions related to the crankcase and cylinder liner fits.

Specifications for cylinder liners, including standard sizes, outside diameters, and protrusion.

Technical data for crankshaft journals, including standard sizes and undersize dimensions.

Specifications for the bearing race for the front crankshaft, including inner diameter.

Dimensions for the thrust bearing journal on the crankshaft.

Data for main bearings, including wall thickness, inner diameter, spread, and marking.

Specifications for the flywheel and starter motor gear ring, including diameters, interference, and teeth count.

Dimensions and wear limits for connecting rods and conrod bearings.

Specifications for pistons, piston ring grooves, and piston rings, including heights and clearances.

Dimensions and wear limits related to the cylinder head, valve guides, and valve seat inserts.

Information on cylinder-head bolt lengths, types, and reusability.

Specifications for valve recess dimensions and valve spring forces.

Dimensions for rocker arm bearing pedestals, rocker arms, camshaft, and camshaft bearings.

Specifications for valve tappet bores and valve clearance settings.

Valve timing specifications and compression pressure limits.

Backlash values for various gear and drive components.

Specific lubrication data for the D 2866 LUE 602 engine, including pressure values and pump delivery volumes.

Lubrication data specific to the D 2866 LUE 605 engine, including pressure and pump delivery.

Dimensions and specifications for the engine coolant pump for D 2866 LUE 602 and D 2866 LUE 605.

Axial and radial clearance specifications for the S3A Turbocharger.

Details on injection nozzles, including manufacturer, type, number of holes, and opening pressure.

Information on the injection pump governor type and start of delivery angles for different models.

Torque values for various screw plugs according to DIN standards.

Torque specifications for crankcase and crankshaft drive components.

Torque values for cylinder-head related fasteners, including spark plugs and rocker arm pedestals.

Torque values for various lubrication system components.

Torque specifications for exhaust and intake manifold mounting bolts.

Torque specification for mounting the starter motor.

General installation tightening torques for bolts and nuts based on property classes.

Notes on cylinder-head bolt types and general tightening principles.

Procedures for initial tightening and retightening of cylinder-head bolts on new engines.

Procedures for tightening cylinder-head bolts after repair work, including initial and retightening steps.

Guidelines for checking the length and surface condition of used cylinder-head bolts before reuse.

List of special tools with figure numbers, designations, and item codes for engine repair.

Visual representations of various special tools used for engine maintenance and repair.

Detailed list of special tools with their corresponding item codes for ordering and identification.

Further listing of special tools and their item codes.

Additional special tools and their item codes.

Specific tools for water pump repair, including support rings for bearing removal.

Diagrams and dimensions for pressing rings used in coolant pump cover repair.