Service-Akademle tay Engine Training Course D 2066 LF.. with EDC7 Common Rail comptes Service-Akademie Gad D20.. EURO 3/4 COMMON RAILService-Akademle Gard [RANGE OF ENGINES Engine Series Nominal power output (Chassis number (080 1985-28105 E50) aging wa: A066 FOL... EuN02. conT@A HO HP 228 KW on WMH D2066LFOR.... Eur02. coonT@A 380 HP 28 KU on WMH D2066LFO2... EuN02.. coonT@A 380 HP 28 KW on WMH 2066 LF... EuN02.. coonT@A $20 HP 1818 non WME Service-Akademle (KEVTO ENGINE TYPE PLATE ENGINE TYPE PLATE Engine type code MAN - Werk Nurnberg | Typ oz0s6LF 01 Motor‘. Engine No. NI/ NIL 505 0404 0948 2F 1 NIN panet et 1 Dimenslonal deviation of 19mm Dimensional deviation of 0.25 mm P_Bigeng bearing journals Hain bearing journals 20... 100 yinderbore,eg. 120 mw eyinder 1610+ 100 marks app. suoke = 195 men No.of cylinders 8= cylinder, 0 = tOcynder Type of feces asian (turbocharger wih charge inverter) Insiaes positon of engi: Forward contol tuck wih vanes angine OH Reavengined bun, vertical engine UH Rear-engred eus, horizontal engine 01 Engine version paticlaty important for spare paris ‘supely, toca! data ant acjusimon valuService-Akademle (ENGINEIDENTFICATIONNUMBER Example: oe 684... Assntly eminent och on dy fase) DB. Orrin ope! © 2. Ovein netanpupiepsting ston FF Oren of arcompesso Gt Seid eminent 9. orge-speed power tokeofh Service-Akademle had (TECHNICAL DATA R6TLEDC (AV) Ginling, vertical 257 KW (350 HP) 1900 tin st 750 New 4000 - 1400 timin 40518 ce see 20 1185 52624 _ateodling-fenend, Cylinder 1 position... Thole 18 Injector pattern Vale clearances, engine cold... exhaust /with EVE. Inlet 0,50 mm 0,60 mm / 0,40 mm ond 20 bar Compression pressure.. Parmizsiblo preseure diference betwean cylindars.max. 4 bar Coddant nee Ol content ccsseersnnnnennsenin 36 max. 42 litres: Fuol cupply system... Bosch EDC 7 Fan coupling hydraulic / electric Dey weight ecnne a 867 hg K value. ct cones 1499 mMService-Akademle p2066.LF o1 EUROS Tp co RO THEDC (4¥) Layout of ender nnn ining, vertical ‘Max power output 316 KW (430 KP) cen 4900 Umi 2100 No 4000-1400 Ahn 10518 ce on 920 185, Firing oer... . co Nee Cylinder # postion. atcooting-fan end sonenT ROle seo A 600 tein Service-AkademleService-Akademle feaccal [CYLINDER LINERS: ‘The wot, replaceable cylinder liners are spacial cantifugal castings. ‘The lower Oxings (1) are coated with a thin layer of engine ci ‘and also the transition to the cylindrical saction of the line. WARNING: [DO NOT USE A BRUSH TO APPLY THE OL. NoTe: ‘Do not use any kind of grease or sealant. ‘top projection by the approved test method (measure witnout the sealing ring). Insert the cylinder liner into the crankeasa without the Qvings Service-Akademle ‘Attach the measuring presstre plate and tighten to 40 Nm. After this, measure withthe dial gauge at not less than 4 points 4 Gylinger tines 2 Grankcase(C) shoulder recess Height of shouleron cylinder liner D=C Measured projecton cf csinder ine rom crankcase + Cylinder liner projection: rnin 0.03 max. 0,085 mm (measure by moars of measuring device without O-ring) + Depth of shoulder recess “G” 7.985 - 8.015 mm 4+ Height of elinder liner shoulder “D" 8.05-6,07 mmService-Akademle PISTON CLEARANCE IN CYLINDER LINER Determining piston clearance: Using the internal measuring gauge, measure the intemal ciameter ofthe cylinder liner on three measuring levels from top to bottom at equal 45-cegree spacings. Read off the piston iametor from the crown of the now piston. Ifthe piston has already been run, use an outside micrometer to measure from the underside ofthe piston at a nght angle tothe piston axis and deduct the piston diamater from the largasteylindar liner diameter previously measured. The value calculated inthis way Js the piston clearance. Service-Akademle Example for piston clearance on D 20.LF Internal eylindet © concnssnesneennens 44999 = 120,04 mm, Piston @ A 119,87-119,88 mm 1121.3 Heights for measuring cylinder diameterService-Akademle [CRANKSHAFT ‘The erankshattie rosiatant to torsion and floxing, and has eight ‘orged-on balance weights to balance out the inertial forces: ‘truns in seven main bearings in the crankcase. The main and big-end bearing journals and the lecating bearing ‘shoulders are induction-nardened and ground. Axial location is by means of thrust washers recessed into the crankcase a the centl bearing pedestal, Warning: the lubricating grooves on thrust washers A must foco ‘he cearkshattwebs, Warning: Never use a hammer or lever to detach te vibration damper. ill malfunction i dented oven alight and this could lead to clutch damage or a broken crankshaft ‘A Crankshaft thrust bearing......... 0,200~0.401 mm 1B Mainbearing BOWS an 300 Ne 80 E Designation H and P — tolerance value Nor NA for big lend or man bearings. NI = 0,1 mm se variation Service-Akademle Variation in boating shells "E*: + Measure *C" + Measure *D” + Veriation = "6" minus "0" +The variation must be 111.2 mm to 112.4 mm (0.3 1.2 mm). + Important: “G* must be laroer than "O* Main bearing journal dameter:.........N 109,98 ~ 104,00 mm Max. main bearing pay. soo M 0,060 ~ 0,116 mm 0,25 ~0,50 mm, 0,75 ~ 1,00 mm Further undersizes: Note: ‘al ain bearing caps are produced by cracking ‘+ tho uppor main bearing choll has an ol holo 4+ the lower main bearng shal has no ol hole “Tighton vibration dampor bolts to 150 Nm+40 Nm torque and 190 +40 af angie hoa Oe A or =Service-Akademle Gas ‘Tre conreds ar prastion dap forged tom “CaBros host. tretabe sto! and she std. The anes beamng aps ae fermedy ertcking The ncned being capa raked peste ‘orate conrad easy upwards, trough the clin, turing overhaul repair werk The upoerBeanng shel sof highly wear-esstrt puted beting mata. ‘The bearing hles of th bond bsanng shots ro maasured we installed recon 7, 2and 3 and at ves an th Bearing hols wth hole win th tleranos ls can bors Used. Thebeanngs must be renewed ithe dmersons are Wolenttorence por ect max. 509 ‘+ upper ig ond searng (GLYO 188) + lower big ond bearing (GLYO 81) Nove: + the upperbearing shell marked TOP or has are pail spot Conte sida (haconod supson shel). Biron bearng journals regula 2)... 898 = 80,00 mm Bl-cnd bearing variaton€ (Mba) 96 5(+2.5+ 0.5} mm Bore spacia 2562 0.02mm Smat-end bearing (neal). 52,000 0.008 mm Big-end bot sgtteningoxaue: Tightoning torque 100 Nm“ plus 90° “Tho conred and matching bg and bearing ca aro arkod ‘enealy at the side, neat he erack ine Waring: ‘Bonet stand the conrd or bg-end bearing cap on the racked surface. he crack patern is damaged oF ‘otherwise changed. the eonrod and cap will no ft together _conctly end may be damaged beyond reps Service-Akademle c as-crossService-Akademie hans [PISTONS “Three-ring pstons made from a special aluminum alloy are used “They have a easton ing carer forthe uppermost piston ring The Ccombusten chamber recess i stepped and has an ‘omage ‘shape. Pockets are previded forthe inlot and exhaust vai ‘hoods. Te provent overheating the pistons have a sastin cling duct (430/800 HP engines) and are cooled by ajot ofl from a ‘spray nozzle “The pistons have been maicied to the higherigntion pressures ‘by stapped support on the coneds and in the combustion cramber ‘+The pistons forthe 430/380 HP engine are cooled by al spray from a cooling passage. To ersare that piston cooling takes place correctly even at lw angi specs, the pressure regulating valve in te cil epray nozzics has boon deleted. ‘+ Pistons for he 350/310 HP engine ave cooled by the well proven drect spray method Service-Akademle ison rings: The compression rings are a double-sided trapezoidal ring and 2 ricra-chamfar rng. Aperthouse-pattamn ol serapering uth tubular spring ie usod, Piston racess/projection at crankcase: Minus 0,03 mm to plus 0,30 mm iston ring end gaps (wear limit) 1 Trapecoidal compression ring wear iit. nf Simm Micro.chamfor compression ring wear lit an. 4,5e0m, ML 01 scraper Wear lit een SO loans) Piston technical data from Alcan) 1. Piston diameter at right angle to small-end eye: ‘Measure the piston 22 mm above is bottom edge. 2 Piston diameter 119,87 t0 119,89 mm, 3. Compression height: Normal: B2D66LF ee aneennnen 7,80 £0 0,05 mm 4. Conter of piston pin eye to piston head A. Piston recess into/projection from top of erankease: =0,03 10+ 0,30mm, Piston ring groove heights (9) Compression ring groove 1 3.418 to+- 0.015 mm, (8) Comprassion ring groove 2 8,04 103,06 mm (7) Oil scraper ting greene enenenenen 405 te 4,02 ram Piston ring heights ‘Compression ring (double-sided trapezoidal ing ) with chrome- ccerame surtace layer Diston ring height CS ee 0.40 t0 ‘Compression rng (micro-charter). 3.0010-0.03 mm End gap 0.47 t00,7 mm il scraper ring Piston ring height. 3.9910 3,97 mm End gap 0,250 0,55 mm Difference in piston woight por sot for any ongino ....max. 60.9 ‘+ Install with arrow pointing forwards. ‘+ Tho small rocess incide the piston body is to claar tho oil spray nozzleService-Akademle Service-AkademieService-Akademle has [CYLINDER HEAD ATTACHMENT The completo ons piace cyndorhoad i atached te the engino ‘block with 26 Torx E 24 (10:8) bolts thal are tghtened to 2 pecied wronch angle. “The cylinder head bots (218 x 2 mm) have Cossnise slines, A Flywheel end Service-Akademle ‘Torxhead bolts for tightoning to a specfie wrench angle 41) Place the cylinder head in positon, align and insert all bal i the speniied numerical onfr (rst apply Optics \WhtoT to the belt heads anol tho bol threads). Tighton {he bots intely to 10 Nm. 12) Next tightening stage 80 Nm torque 3 Nestightering stage 300 Nm torque 4) Nextightonng toge 99° 10° dogreos of angla 5) Fina tgtenng stage 80" + 10" degrees of angle 16) Final ghtonng tage 90° + 40° dogroos of anale Note: There fs now no need for any slack to be taken up subsequently at tho cylindor head bolts. Note comect tightening sequence (picture {..2..3.) ulindes head bolts must never be ressed.Service-Akademle ‘Single-piece 4-valve cylinder head, inlet and exhaust valve sides The inlet and eshaust valves have positive clamping at the 3 ‘groavesin tho tom and the wodge-shapod koys. ll valvos aro provided wit valve stem seals io keep cll consumstion toa Inletvalvo identification: ‘Spherical recess "A" with big in valve head for outet valve ‘Spherical recess "B* with small in valve rae for inet valve + Inlet vake diameter 40,0 + 0,4 mm ‘+ Exhaust valve diameter 38,0 +. 0,1 mm ‘+ Inlet valve recess n cylnder ead 0,60 ~0.80 mm 1+ Sehaustvave recess in oylnder a 6,60 ~ 0,80 ram ‘The EVE mochaniem ie builtinto exhaust vaive bridge "2", ‘The 1ockeranms and ihe EVB are supplied wih cl rom the rocker am puot basring housing, The EVB counter-naéer is located soparatal. Service-Akademle " rn 2 “4 8 Phunger Vale bridge Counter heldor Leckout (5 Nm tightening torqus) VB adjusting sew (0,40 mm) Ballonded adjusting crew (0,60 mm) Lockout (5 Nm ighiening torque) Rocker aim sat Rocker arm camera Inlet valve adjusting screw Inlet valves Eshauetvalves Rolerbeating rocker arms camera Inlet vaive seat angle 120° Exhaust valve seat angle 80°Service-Akademle had [REMOVING AND INSTALLING INJECTORS ‘Removing the injector 1, Detach the injector pipe and plug is opening, 2. Remove pressure nut & from the pressure sk pipe 4 2. Take out pressure stub pipe 4 using the special tool 4. Remove pressure-lange bolt 6 and clamp 5, 5. Pullout the injector wih the special oo! and keepit ina ‘special safety box. Nore: Pressure stub pipe 4 must not be re-used: avays renew the O- fing 3 and the copper washer 2a wel. Aller mounting the ijectrit is recommenced to perform a Jeakage test (explanation on page 83) Installing the injector ‘Only remove the trait caps immediately for instalation on the engine Initial tightening of injector with machine sorew(8). 102 Nem 1B) Install the thinner end of pressure st pipe (4) towards ‘ho injoctor. Inital tightening ef prescuro nut 10 Nm C)_ Final tgniening. inector machine screw (6):25.1Nm +90" 1D} Final tghicning, proseure stub pips (4): 20 Nm + 60° £) Connecting high-pressure lines from and to rat > Screw up the rail rataning screve hand tight only Bx a xs0- 10.9) >t" stop: Tighten allinjoctor pipes frmiy at both onde to 10Nm torque 2° step: Tighten rail to 35Nmtorque. > Final tightening ofall injectorpipes 10 Nm + 60" F) Tightening torque for Mi ~ 1,5 Nm Key 1 Oring (grease defore installing) 2 Coppershim 3 Onn 4 Pressure stub pipe 3 Clamp 6 Pressure flange belt 7 Conical washer 8 pressure pparut Service-Akademie feacane) INSTALLED CLEARANCES AND WEAR LIMITS ‘Main beering journal ciameter ~ standard size ‘Main bearing play -N ‘Variation between man beating shell (Crankshaft endlay Big end bearing journal diameter ~ standard size Big end bearing internal diameter ~ standard size Variation between big ond bearings ‘Gudgeon pin internal diameter (Cylinder liner projection above engne block PPiston projection above top of engine block ‘Compression height, standard dimension (undersizes 0.2 -0.4 0.6) Installed dimensions Wear 103,98 - 104,00 mm 0.06 - 0,116 mm 03-1,2mm 0,200 0,401 mm 89.98 -90,00mm (90.060 - 90.102 mm 95,5 —(62.5/-0,5) mm 132,000 - 0,008 mm 0,030 0,085 mm 003-+0,3 mm 79,25 mm. max. 1,25 mm min, 0,030 mmService-Akademie 1 Compression ring 2 Compression ring 3 Ol scraper ring Exhaust valverecess Inlet valve recess Inlet valve clearance Exhaust valve clearance wih EVE Service-Akademie [D20cRTIGHTENINGTORQUESOOSOSC~C“—SC“SSC“~SC“s~Ss“‘“‘SSS Cd Installed dimensions 0,40 - 0,55 mm 0,47 - 070mm 0,25 - 0,55 mm 0,60 - 0.8mm 0,60 - 0.8mm 05 mm 08 mm 06 mm Kem Thread | sxengtn| Tightening | initia! | Tahtening Remarks oa | analo.x 1_| Main bearing cap to crankcase IM 18x2 10.9 ee 300+30 £0°+10" Do not re-use screws 2 [Larue intermediate aearwhee! cin [M14 10.9 iM 90° 3 [Thrust washer atuming ase [Ms 29) m7 [4 [Camshat gearvhosl wo camshat | wiexis | “09 0 sso | 00" 5 Fwhostie rantshat iets [109 “ao116 | 90" Nai ber used [5 [Bixend cap to cemociea ed [wiz | 11.9 ‘oov0 | soe10" Noto be o-used 7 [Recker bearing pedesia to cyinead|Mi2_—_| 10.9 “0540 [Lockout a adjusting srow wind [109 a ¢[Esnaust manifold to cvinder head [M0 Ss Tone 0 | Fae start gro.heat pun aac mane a : ial iting 60° 11 [ctor tos as vo | coro ta ing 6” 72 GR nese we connection ia Te 73 | Cento unt decouping Ma nH 242 Toate 270 “4 Hah-prossure punp deve gear 758 15 Ribbed V-belt pul to stem [MBC 05 76_[ Vbration damper miexis | 109 sono | oor 77 Ceoing fen hub to fan Salt M6 00 | -eo"+10" [ethanditivead| 8 | Ait compressor ve goar wats weo [9 [ pressure oto vave at compressor Zax 2950 20_[Fitor cover foro module 406410 * | cytinder head batts M18x2 10.9 10 +80+ 300 ‘3x90°+10" Optimal White T (oll)