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    47 views28 pages

    MAN D2840-42 LE301 Service Data

    Uploaded by

    Dilawar Ali
    Service data

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
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    149 Service Data Specifications Engine D 2840 LE 301 Design 4-stroke diesel with turbocharger / intercooler and charge-air regulation (waste gate)Waste Gate) Number of eyinders Compression ratio Bore Stroke Engine capacity Direction of rotation viewed on flywheet Firing order Power based on DIN ISO 3048 D 2840 LE 301 Lubrication . forced feed lubrication by gear cll pump Filling capacities ii capacity in the oil pan deep . ii capacity in the oil pan shallow Oil change capacity (with fier) deep Oil change capacity (with fier) shallow Cooling by impeller pump Coolant temperature normal temporarily Filling capacitios Engine with heat exchanger va0" 10 155:1 428 mm 142 mm 18270. m3 anti clockwise 1-6-5-10-2-7-3-8-4-9 see engine nameplate Pressure circulation -min. 26 It, max. 30 tr. min, 98 Ir, max. 48 Ir, 3 it. 51 It. Fiuid cooling 82-86°C 95°C 80 tr. 150 Specifications Engine D 2842 LE 301 Design v0" 4-stroke diesel with turbocharger / intercooler and charge-air regulation (waste gate)Waste Gate) Number of cylinders 2 Compression ratio 15551 Bore 128 mm Stroke 142 mm Engine capacity 21.930 om? Direction of rotation viewed on flywheel anti clockwise Firing order 1-12-5-8-3-10-6-7-2-4-4-9 Power based on DIN ISO 3046 0 2842 LE 901 see engine nameplate Lubrication Pressure circulation forced feed lubrication by gear oll pump Filing capacities il capacity in the oii pan deep Oil capacity in the oil pan shallow Oil change capacity (wit fiter) deep Oil change capacty (wih fiter) shallow Cooling by impeller pump Coolant temperature normal temporarily Filling capacities Engine with heat exchanger min, 24 Ite. max, 32 fr. min. 60 Ir max. 70 Ir 36 tr. 73. Fluid cooling 82-86°C 95°C 96 tr. 151 Service Data Dimensions Limit values Crankease standard size: 188,90-154,00 mm for liners with larger outer diameter: 5 and 1,0 mm: 154,40-154,50 mm standard size: 145,80-145,84 mm for liners with larger outer diameter: 0,5 mm 148,20-146,34 mm 4,0 mm 146,80-146,84 mm 9,97-9.99 mm standard size 144,50-144,54 mm {or liners with larger outer diameter 0.5 mm: 148,00-145,04 mm 1,0 mm: 145,50-145,54 mm standard size: 159,694~153,757 mm with larger outside diameter 0.5 and 1,0 mm: 184,194~154,257 mm standard size: 10,030-10,050 mm with more flange height: 0,2 mm: 10,230-10,250 mm ner protrusion above upper deck ot crankcase: 0,04-0,08 mm standard size: 145,761-145,786 mm with larger outside diameter 0, mm: 146,261~146,286 mm 1,0 mm: 146,761-146,786 mm 127,990-128,010 Max. wear limit 0.15 mm below base dimension standard size: 144,492-144,457 mm with larger outside diameter 045 men: 4,0 mm: 144,932-144,957 mm 145,432-145,457 mm 152 Service Data Dimensions Lo ~, Limit values Pe Crankshaft Crankshaft front end (opposite end to flywheel) 99,985-100,020 mm Standard size: 89.98-90.00 mm undersize -0.25: 89.73-89.75 mm Uundersize -0.60: 89.48-89.50 mm undersize -0,75: 89.23-89.25 mm undersize -1.00: 88,98-89,00 mm Standard size: 108.98-104.00 mm undersize -0.25: 103.73-103.75 mm undersize -0.50: 103.48-103.50 mm undersize ~0.78: 103.23-103.25 mm undersize ~1.00: 102,88-103,00 mm 1 = Colour marking for size identification of crank pin diameter 2 = Colour marking for size identification cof main bearing journal diameter Undersize 0,25: red Undersize 0,50: white Undersize 0,75: yellow Undersize 1,00: lilac Permissible axial clearance of crankshaft 0,190-0,822 mm Bearing race for crankshaft, front end Inner diameter: 99,907-99,942 mm 153 Service Data Dimensions Limit values Crankshaft rear end 7 (adjacent to flywheel) pueni Pr eaten ern eco dl | Sea Max. permissible runout with crankshaft taken up in end beatings: 0 2840 at bearing 0,06 mm at bearing 4 0,06 mm D 2842 albearing 4 0,08 mm. 38,000-38,062 mm 38,500-38,562 mm 38,500-38,562 mm 38,000-39.062 mm 39,000-39,062 mm 1 = Colour marking for size identification of thrust bearing journal length Standard size: undersize -0.25: undersize -0.50: undersize -0.78: undersize ~1,00: undersize -0,26: red Undersize -0,50: white Undersize -0,75: yellow Undersize 1,00: flac Main bearing Data for wall thickness and bearing inner diameter also apply to the align- ‘ment bearing 8.485-3.467 mm 3.580-3,592 mm 3.705-3.717 mm 3.890-3.842 mm 3,985-3,967 mm Standard size: undersize ~0.25: undersize ~0.50: undersize ~0.75: undersize ~1.00: Internal bearing © when filed Standard size: 104.066-104.112 mm undersize -0.25 103.816-103.862 mm undersize -0.50: 103.586~103.612 mm lundersize -0.7: 103.316-103.962 mm lundersize -1,00: 103,086-103, 112 mm Spread 0,3-1,2 mm Marking: top / bottom standard size: 0958 / 0079 mm undersize -0.25: 0962/0081 mm undersize ~0.50; 0964 / 0082 mm undersize -0.75: 0966 / 0083 mm undersize -1.00: 0968 / 0084 154 Service Data Dimensions a Laue canes [ae Thrust bearing Standard size: 97.74-87.61 mm undersize -0.25: 98.24-38.31 mm undersize -0.50: 38,24-38.31 mm undersize -0.75: 98.74-38.81 mm undersize -1.00: 38,74~38,81 mm Spread: 0,1-0,5 mm Marking: top / bottom standard size: 0164/0165 mm undersize -0.25: 0168 / 0169 mm undersize -0.50: 0170/0171 mm undersize -0.75: 0172/0173 mm ndersize -1.00: 0174/0175 31,01-31,04 mm Data for wall thickness and bearing bore see "main bearing” Mounting bolts for crankshaft bearing caps Length With each tightening, the bolts are deliberately stressed beyond the stretch limit and each tightening thus extends their length permanently. When the max. length has been reached, the bolt may no longer be used. new: — 1825-163 mm max: 154.5mm 155 Service Data Dimensions Limit values fenod Flywheel and starter gear ring oe ry Flywhes!: 432,490-432,645 mm Internal gear ring @: -432,000-492 185 mm Interference: 0,835-0,645 mm Installation temperature: 200-230°C Number of teeth: Z = 160, module 3 Matching gear: Starter pinion (Z = 9) Gear ratio: i= 17,78 Backlash: 0,6-0,9 mm 156 Service Data Dimensions Limit values fam Conrods 46,055-46 065 mm Wear limit: 46,06 mm Bearing bore in measuring directions 1, 2 and 3 and in measuring planes a and b: 90,075-90,120 mm Edge condition: New conrod bearing in place, conrod as- ‘sembled Standard size: 2.463-2.473 mm undersize -0.25: 2.588-2.598 mm undersize -0.50: 2.713-2.728mm undersize -0.75: 2.898-2.848 mm undersize -1.00: 2,968-2,973 mm Spread: 0,6-1,5 mm Hf signs of wear are presant (scores,antiwaer coating damaged), ‘change both bearing shells Important: Observe installation position (od shell has red colour markings on the side) 187 Service Data Dimensions Limit values Pistons Compression height: 81,250-81,300 mm with undersize 0,2 mm: 81,050-81,100 mm (0,4 mm: 80,850-80,900 mm 0,6 mm: 80,650-80,700 mm Piston protrusion above crankcase top: 0,01-0,38 mm, 46,005-46,013 mm Piston bolt diameter: 45,984~46,000 mm 127,835-127,875 mm Max. difference in weight per engine pis- ton set: 1009 Piston ring grooves + | Lp 93,455-3,485 mm 3,040-3,060 mm -| 4,020-4,040 mm Piston rings string ~ keystone ring Height: 3,296-3,330 mm 2nd ring ~ Minute ring: Height: 2,978-2,990 mm ‘Axial clearance:0,050-0,082 mm 3rd ring - bevelled ring Height 3,975-3,990 mm Axial clearance:0,030-0,062 mm Ring gap’ t.st ring: 2rd Ring: 3rd Ring: 158 Service Data Dimensions Limit values Cylinder head 12,000-12,018 mm intake valve 12,000-12,018 mm Exhaust valve 17,1-17,5 mm Intake vaive a = 60° Exhaust valve B= 45° Valve guide bore in cylinder head: 18,000 ~ 18,018 mm Valve guide outside diameter: 18,028-18,046 mm standard: 113,9-114 mm minimum: 12,9 mm (observe specified dimensions for valve recess and injector projection, ‘see page 160) Valve seat insert hore in cylinder head: 153,00 ~-53,03 mm \Valve seat insert outside diameter: 53,10-89,11 mm Valve seat insert bore in cylinder head: 61,00 - 61,03 mm Valve seat insert outside diameter 61,10-61,11 mm 169 Service Data Dimensions Limit values Cylinder head bolts (6kt- oder Torx-Kopf) ARG Length With each tightening, the bolts are deliberately stressed beyond the stretch limit and each tightening thus extends their length permanently. When the max. length has been reached, the bolt may no longer be used. ‘Angle of rotation symbol ew: 167,5-168 mm, max. 170 mm new: 143,5-144 mm, max. 148 mm ew: 108,5-109 mm, max. 111 mm Valve recess Intake valve: 11,969-11,980 mm Exhaust valve: 11,944-11,955 mm Max. wear limit: 0.1 mm below base dimension Do not reuse vaives with damaged chro- rium layer! Valve recess for intake and exhaust valve: 07-13 mm Valve springs Inner spring: Free lenglh (L), approx. 65,5 mm Spring force at 46,9 mm: 131-155 N Spring force at 32,3 mm: 260-300 N Outer spring Free length (L), approx. 59 mm Spring force at L46,46,8 mm: 390-360 N ‘Spring force at L* = 32,8 mm: 710-770 N ‘The lowest spring force is at the same time the wear limit value. 160 Service Data Dimensions Limit values Valve gear Rocker arm bearing pedestal 24,967~24,980 mm. Kipphebel Rocker arm radial clearance: 0,025-0,054 mm Wear limit: 0,08 mm 25,005-25,021 mm Valve clearance Valve clearance (cold engine) Intake valve: 0,5 mm Exhaust valve: 0,5. mm. 161 Service Data Dimensions Limit values aan Camshaft Feplace if there are traces of wear ‘Camshaft axial clearance: 0,20-0,90 mm ‘Wear limit: 1,5 mm 69,910-69,940 mm Backlash: Crankshalt whee! and camshatt wheel 0,118 mm-0,242 mm Camshaft bearing Valve tapped 70,000-70,030 mm or 70,070~70,090 mm for bush § (V8), 6 (V10) or 7 (V12) = bush at timing case end ‘Bore in crankcase: 20,000-20,021 mm 19,944-19,965 mm 162 Service Data Dimensions Limit values Valve timing sagine direction of turn intake valve opens 24 ° before TOC. = exhaust valve closes 36 ° after TDC 4-= exhaust valve opens 63 ° before BOC. 5 = intake valve closes 27 ° after BDC 6 = Exhaust open for 270° 7= Inlet open for 240° ‘The degrees specified refer to the crank shaft angle Compression pressures good permitted repair required Pressure diference (between the individual cylinders) above 26 bar 23-26 bar below 23 bar max. 4 bar 163 Dimensions Service Data Limit values Engine lubrication Valve opening pressures Bypass valve for oil filter 2,2-2,8 bar COverpressure valve on the oil pump 9-10 bar Pressure valve ofthe ol injection nozzles Opening pressure 1,68-1,9 bar Pressure al max. opening 1.9-1,6 bar Oil pump 3-gear oil pump Gear width: 34 mm Shaft 21,930-21,940 mm Bore Qin housing: 22,000-22,021 mm Radial clearance 0,080-0,091 mm Press on force: 12200N i Housing depth: .34,000-24,039 mm ‘Avial clearance: 0,050-0,128 mm Ls ~—| 33,911-33,950 mm ————} 14,5-14,7 mm Drive wheel with oil pump wheel Se. 145-147 mm Shatt 21,930-21,940 mm Bore incrive gear: 21,870-21,885, mm Press on force: 12000 N Backlash: Drive wheel and crankshaft wheel: 0,099-0,451 mm 164 Service Data Dimensions Limit values il pump Oil pump wheel Gear width 43 mm Shaft 21,930-21,940 mm Bore @ in housing: 22,000-22,017 mm Racial clearance —_0,040-0,108 mm. Press on force: 12200 N Housing depth 43,000~43,039 mm ‘Axial clearance: 0,050-0,128 mm 42,950-42,911 mm 11,5-11,7 mm 14,5-11,7 mm, Shatt: 21,930-21,940 mm Bore in drive gear: 21,870-21,885 mm Press on force: 12000 N Backlash Drive wheel and crankshaft whee! 0,099-0,451 mm 165 + ; Dimensions btbaeidaaatel Limit values Gan Cooling system Engine coolant pump 2p 0,7-0.8 mm © impetier: 149,5-160 mm Bearing seat in housing: 54,940-54,970 mm @ of bearing Interference: 54,981~54,994 mm 0,011-0,054 mm Bore for bearing shaft in impeller: 16,008-16,010 mm of bearing shatt: 16,045 ~16,056 mm Interference: 0,035-0,048 mm Bore in hub: 25,007~25,020 mm Gof bearing shaft: 25,048 ~ 25,061 mm Interference: _0,027-0,054 mm 166 Service Data Dimensions Qo Limit values eee Cover for heat exchanger iller cap with safety valve: Safely valve with imprint 1.5 opens at 1.3 bar-1.7 bar above atmospheric pressure Valve cover: Working valve with imprint 1.0 opens at 0.85 bar-1.15 bar above atmospheric pressure and 0.02 bar -0.08 bar below ‘atmospheric pressure Warning: If the cap with the working valve is ‘opened, there is the risk that it will not close tightly again afterwards ‘The excess pressure required in the sys- tem wil then no longer build up. Prema- ture boiling occurs and coolant is lost To prevent damage to the engine open this cap only in exceptional circumstances cor during service work and fit a new one as soon as possibie. Thermostat ‘Opening begins at: 82-86°C (2°) Fully open: 95°C (2°) Lift atleast: 9,5 mm at 95°C (The temperature for the start of opening is printed on the thermostat) Change seal it thermostat is removed 167 Dimensions la Injection pump Service Data Limit values Fuel system Injection nozzles Manufacturer Bosch “Type of injector DLLA 146 P 581 Number of holes 6 Opening pressure of injector New nozzle halder: 29518 bar Used nozzle holder 28048 bar Bosch-In-line pump Governor Start of delivery Mode! 02840 LE 301 1500 1/min, constant 1800 4/min, constant D 2842 LE 301 1500 1/min, constant 1800 1/min, constant Electronic speed governor (GAG) rank angle before TOC. ‘optimised consumption optimised NOX ate 10" =1° 121% isto optimised consumption optimised NOX 147219 40° 1% 16215 4gr=1° 168 Dimensions Service Data fan Limit values Starter motor Manufacturer: Bosch Type: KB Operating method: splined shaft Starter mator pinion: Number oftesth: Z=9 Module: 3 Nominal power: 6.6 kW Nominal voltage: 24 Power take-off for hydraulic pump Uj '52,000-82,046 mm Pin diameter: 29,959-29,980 mm Bearing bore: 30,020-30,041 mm Speed of power take-of engine speed x 1,26 (i= 0,791) Backlash: 0,098-0,330 mm 169 Torque guide values boas Wte © Aion comectons whose purposes ot sated in th fotowng al art ethene in tccoarce he gle sees eu Company sanréM S05 (ee page 179) ro ols Bint ola! Plugs DIN208 Mga 5, MI6xt.5 20 Nn Wax 8 22x 8 5 400 Nin eee 8, MZ6xt 5 420 Nm annex 8 460 Nm DIN 7604 AMOR, MY2x1 5 0 Nm atten 0 Nin Crankcase, crankshaft drive Gear case to crankcase M10, 129 225 Nm Gear ave io crankcase M10, 129 75m Gear case o crankcase MI2x1.5 128 ‘co Nm Inspection pon cover to gear caso Me, 129 40Nm Timing case cover to crankcase ME, 10.8 25Nm 1 Sf Sa

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