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Man D2862 LE221 User Manual

Man D2862 LE221
420 pages
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MANIndustrialDieselEngines
D2862LE221
D2862LE223
Copydeadline:05.2015
RepairManual
51.99598-82623steditionAE6
MANTruck&BusAG
Vogelweiherstraße33
90441Nürnberg
oder
Postfach440258
90441Nürnberg
ReparaturanleitungAE6,3.Ausgabe
MAN-Industriedieselmotoren
D2862LE221
D2862LE223
-Englisch-
PrintedinGermany

Table of Contents

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Man D2862 LE221 Specifications

General IconGeneral
Engine ModelD2862 LE221
CategoryEngine
Cooling SystemWater-cooled
Fuel SystemCommon Rail
AspirationTurbocharged
Number of Cylinders12
Displacement24.24 L
Emission StandardEU Stage IIIA

Summary

INTRODUCTION

Safety Instructions and General Information

Provides essential safety guidelines, regulations for preventing injury, and information on engine operation and suspended loads.

Working on Common Rail System and Dirt Prevention

Details safe practices for common rail systems, including dirt ingress prevention and pacemaker considerations.

Engine Operation, Assembly, and Warranty

Covers engine operation with ECUs, assembly instructions, and manufacturer warranty details.

Engine Systems Description and Identification

Explains engine identification, model designation, characteristic data, and describes mechanical, fuel, and electrical systems.

COOLING SYSTEM

Cooling System Procedures

Details removal, installation, and technical data for the cooling system, ramfan, intermediate flange, coolant lines, and thermostat.

ADD-ON UNITS

Starter Removal and Installation

Covers procedure, additional jobs, technical data, and important information for the starter.

Fan V-Belt Removal and Installation

Covers procedure, additional jobs, technical data, and important information for the fan V-belt.

Fan Tensioning Pulley Removal and Installation

Covers procedure and additional jobs for the fan tensioning pulley.

Fan Carrier Removal and Installation

Covers procedure and additional jobs for the fan carrier.

Poly-V-Belt Removal and Installation

Covers procedure and additional jobs for the poly-V-belt.

Automatic Belt Tensioner Removal and Installation

Covers procedure and additional jobs for the automatic belt tensioner.

Guide Roller Removal and Installation

Covers procedure and additional jobs for the guide roller.

Alternator Removal and Installation

Covers procedure, additional jobs, technical data, and service products for the alternator.

COMMON RAIL SYSTEM

Common Rail System Overview and Component Identification

Provides an overview of common rail system components, identifying key parts through image labels.

High-Pressure Lines and Rails Procedures

Covers removal, installation, additional jobs, and technical data for high-pressure lines and rails.

Injector Procedures

Details removal, installation, additional jobs, and technical data for injectors with nozzles.

Common Rail System Component Removal and Installation

Covers procedures for injector, rail, leakage lines, rocker arm mechanism, and pressure loss testing.

High-Pressure Pump Procedures

Covers removal, installation, additional jobs, technical data, and component procedures for the high-pressure pump system.

Fuel Lines and Filter Procedures

Details removal, installation, additional jobs, and component procedures for fuel lines and the fuel filter.

Hand Pump Procedures

Covers removal, installation, and component procedures for the hand pump.

TURBOCHARGING

Turbocharger and Charge Air Manifold Procedures

Covers removal, installation, additional jobs, technical data, and important information for turbochargers and charge air manifolds.

INTAKE/EXHAUST SYSTEM

Intake/Exhaust System Component Overview

Identifies intake and exhaust system components, including air distribution pipes and filters, via image labels.

Combination Air Filter Procedures

Covers removal, installation, and related components for the combination air filter.

Combination Air Filter Holder Procedures

Covers removal, installation, additional jobs, and important information for the combination air filter holder.

Air Distribution Pipes Procedures

Covers removal, installation, additional jobs, and technical data for air distribution pipes.

Exhaust Pipes Removal and Installation

Covers procedure, additional jobs, technical data, and important information for exhaust pipes.

CYLINDER HEAD

Cylinder Head Component Overview and Cover Procedures

Identifies cylinder head components and covers cylinder head cover removal and installation.

Rocker Arm Mechanism Procedures

Covers rocker arm mechanism removal, installation, dismantling, assembly, technical data, and important information.

Cylinder Head and Valve System Procedures

Covers cylinder head removal/installation, valve stem seal replacement, and valve clearance adjustment.

VALVE TIMING

Valve Timing Component Overview and Camshaft Procedures

Identifies valve timing components and covers camshaft removal, installation, and bearing procedures.

Valve Timing Checking Procedures

Covers checking valve timing, additional jobs, technical data, and important information.

FRONT TIMING GEARS/REAR TIMING GEARS

Timing Gear Assembly and Procedures

Covers front and rear timing gear assembly overview, removal, installation, and related procedures.

ENGINE LUBRICATION

Engine Lubrication Component Overview

Identifies oil modules and oil sump via image labels.

Oil Modules Procedures

Covers overview, removal, installation, component removal, and dismantling/assembly of oil modules.

Oil Injector Nozzles Removal and Installation

Details procedure, additional jobs, technical data, and important information for oil injector nozzles.

Oil Sump Removal and Installation

Covers procedure, additional jobs, technical data, and important information for the oil sump.

Oil Pumps Procedures

Covers removal, installation, component removal, and component installation for oil pumps.

CRANKSHAFT OIL SEALS

Crankshaft Oil Seals Overview and Front Seal Procedures

Identifies crankshaft oil seals and covers front radial shaft seal removal and installation.

Rear Radial Shaft Seal Procedures

Covers procedures related to the rear radial shaft seal, with some potential content overlap.

CRANK MECHANISM

Crank Mechanism Component Overview

Identifies flywheel, pistons, and vibration damper via image labels.

Vibration Damper Removal and Installation

Covers procedure, additional jobs, technical data, and important information for the vibration damper.

Flywheel Removal and Installation

Covers procedure, image labels, technical data, and important information for the flywheel.

Pistons and Connecting Rods Procedures

Covers piston/connecting rod removal, installation, measurement, and related technical data.

Crankshaft Procedures

Covers crankshaft removal, installation, timing gear setting, crankcase bolt procedures, and bearing measurements.

CRANKCASE

Crankcase Component Overview

Identifies crankcase components like vent lines, flywheel housing, engine mount, and cover via image labels.

Positive Crankcase Ventilation Procedures

Covers removal, installation, additional jobs, important information, and special tools for the positive crankcase ventilation system.

Cover and Cylinder Liner Procedures

Covers cover removal/installation, coolant sensor removal, flywheel housing procedures, and cylinder liner removal/installation.

Engine Mount Procedures

Covers engine mount removal and installation, including additional jobs and important information.

TECHNICAL DATA

Torque Specifications for Engine Systems

Provides tightening torques for engine electrics, cooling, add-on units, common rail, fuel, turbocharging, intake/exhaust, cylinder head, and valve timing systems.

Mechanical Component Specifications and Measurements

Details specifications for camshaft, timing gears, oil pump, crankshaft drive, pistons, rings, crankshaft, bearings, and crankcase.

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