7/18/2019
MAN D0836_CR_en
Engine training
course
D 0834/36.
Euro 3/4
Common Rail
EDC 7
AT 01b
http://slidepdf.com/reader/full/man-d0836cren
Produced by
Plank/Schier
MAN Service Academy Steyr
Status 06/2005
1/121
7/18/2019
MAN D0836_CR_en
This document is intended to be used exclusively for
training and is not covered by the ongoing update and
amendment service.
2005 MAN Nutzfahrzeuge Aktiengesellschaft
Reprinting, copying, publishing, editing, translating, microfilming and
storing and/or processing in electronic systems, including databases and
online services, is not permitted without the written permission of MAN.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 2
2/121
7/18/2019
MAN D0836_CR_en
CONTENTS
CONTENTS...................................................................................................3
ENGINE SPECIFICATION.............................................................................5
ASSOCIATION OF POWER UNITS WITH RANGES AND VEHICLE TYPES.6
EXPLANATION OF ENGINE CODE ............. .................. .............. .............. ...7
ENGINE IDENTIFICATION NUMBER............................................................8
DESIGN AND PRINCIPLE OF OPERATION..................................................9
ENGINE SPECIFICATIONS .............. .............. ............... .............. .............. .10
CRANKCASE..............................................................................................22
CYLINDER LINERS.....................................................................................24
CRANKSHAFT.. .............. ................ ............. .................. .............. .............. .26
CRANKSHAFT SEALING RINGS ............. .............. ............... .............. ........ 28
TIMING GEAR HOUSING............................................................................30
CONNECTING ROD....................................................................................32
PISTONS ....................................................................................................32
CAMSHAFT.................................................................................................32
VALVE TIMINGS...... .............. ............... ................. ............... .............. ........ 32
ENGINE TIMING ............. .................. .............. ............... .............. .............. .32
ENGINE OIL CIRCULATION ............. .............. ............... .............. .............. .32
BELT DRIVE ...............................................................................................32
CYLINDER HEAD........................................................................................32
CYLINDER HEAD FIXING...........................................................................32
CHECKING AND ADJUSTING VALVE CLEARANCES................................32
TIGHTENING INJECTOR ON CYLINDER HEAD.........................................32
ROCKER MECHANISM...............................................................................32
EXHAUST VALVE BRAKE..... ................. ............... .............. .............. ......... 32
EVB - SERVICE INFORMATION / EXHAUST BUTTERFLY VALVE
UNCONTROLLED ...................................................................................... 32
INLET MANIFOLD ...................................................................................... 32
EXHAUST GAS RECIRCULATION ................ ............... .............. .............. .. 32
TURBOCHARGER...... .............. .............. ............... .............. .............. ......... 32
TWO-STAGE CONTROL VALVE ............ ............... .............. .............. ......... 32
CHARGE PRESSURE CHARACTERISTIC. .................. .............. ............... . 32
TURBOCHARGER...... .............. .............. ............... .............. .............. ......... 32
PREVENTION OF ACCIDENTS - COMMON RAIL CLEANLINESS. ............ 32
COMMON RAIL SYSTEM WITH EDC 7 ENGINE CONTROL UNIT........ ..... 32
LOW-PRESSURE SECTION................... ............... .............. .............. ......... 32
HIGH-PRESSURE SECTION............... .............. ............... .............. ............ 32
CR HIGH-PRESSURE PUMP CP3.................. .............. .............. ............... . 32
REMOVING/FITTING HIGH-PRESSURE PUMP.... .............. .............. ......... 32
RAIL ........................................................................................................... 32
INJECTOR.................................................................................................. 32
SPEED SENSORS ..................................................................................... 32
MAN CATS 2 ENGINE DATA........ .................. .............. .............. .............. .. 32
ACCELERATION TEST ............ ............... .............. .............. .............. ......... 32
COMPRESSION TEST............................................................................... 32
WATER PUMP................ ................ ............... ............... .............. ............... . 32
COMPRESSOR .......................................................................................... 32
GLOW PLUG STARTING SYSTEM ............... ............... .............. ............... . 32
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 3
3/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 4
4/121
7/18/2019
MAN D0836_CR_en
ENGINE SPECIFICATION
New features of the Euro 4 engine compared with Euro 3 engines:
Engine D 036 .. Common Rail
Injection system
Reinforced crankcase
Reinforced crankshaft bearings
Cylinder head (channel feed)
Connecting rod
Common Rail EDC 7
Pre-supply pump ZP 18
Fuel-lubricated high-pressure pump CP 3
Injection pipes / High-pressure pipes
Oil injection nozzles
Optional turbocharger (2-stage)
Enhanced exhaust gas recirculation
Star-type fuel filter
Injectors with two-part armatures and 8 hole-type nozzles
AGR blocking valve with stepless control
Engine oil for Euro 4 engine to MAN standard (M3477)
Exhaust gas retreatment system:
PM catalytic converter (with OBD sensors)
Additional silencers
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 5
5/121
7/18/2019
MAN D0836_CR_en
ASSOCIATION OF POWER UNITS WITH RANGES AND VEHICLE TYPES
HGV / Bus engines
Emissions class
Vehicle type
Trade designation
Chassis No.
D 0834 LFL 40
Euro 3
TGL/M
xx. 150 BHP (110KW)
WMA
D 0834 LFL 41
Euro 3
TGL/M
xx. 180 BHP (132KW)
WMA
D 0834 LFL 42
Euro 3
TGL/M
xx. 206 BHP (150KW)
WMA
D 0836 LFL 40
Euro 3
TGL/M
xx. 240 BHP (176KW)
WMAH
D 0836 LFL 41
Euro 3
TGL/M
xx. 280 BHP (206KW)
WMAH
D 0836 LFL 44
Euro 3
xx. 326 BHP (240KW)
WMAH
D 0836 LOH 41
Euro 3
BUS
xx. 240 BHP (176KW)
WMA
D 0836 LUH 41
Euro 3
BUS
xx. 240 BHP (176KW)
WMA
D 0836 LOH 40
Euro 3
BUS
xx. 280 BHP (206KW)
WMA
D 0836 LUH 40
Euro 3
BUS
xx. 280 BHP (206KW)
WMA
D 0834 LFL 50
Euro 4
TGL/M
xx. 150 BHP (110KW)
WMAH
D 0834 LFL 51
Euro 4
TGL/M
xx. 180 BHP (132KW)
WMAH
D 0834 LFL 52
Euro 4
TGL/M
xx. 206 BHP (151KW)
WMAH
D 0836 LFL 51
Euro 4
TGL/M
xx. 240 BHP (176KW)
WMAH
T-GA, TGL/M
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 6
6/121
7/18/2019
MAN D0836_CR_en
EXPLANATION OF ENGINE CODE
Engine nameplate
Engine type designation
D 0836 LF 43
MAN - Werk Nürnberg
Typ D0836 LF44
Motor- Nr. / Engine-no .
209 0062 5015 2 0 1
N I / N II
P1
Block N I / N II
D
Fuel type (diesel)
08
+ 100 = Bore diameter e.g. 128 mm 
3
3x10+100 is approximately equal to the stroke in mm = 125
6
Number of cylinders 6 = 6 c ylinders,
L
Charging type (turbocharger with charge air cooling)
F
Engine orientation
OH
Bus rear-mounted, vertical engine
UH
Bus rear-mounted, horizontal engine
43
Engine variant, particularly important for technical data
and set-up values and procurement of spare parts
I
Dimensional variation 0.10 mm
II
Dimensional variation 0.25 mm
P
Big end bearing journal
H
Main bearing journal
S
Camshaft mushroom tappet (S1 0.25 mm oversize)
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 7
7/121
7/18/2019
MAN D0836_CR_en
ENGINE IDENTIFICATION NU MBER
Example: Engine number
Engine type code
A
209
B
0062
C
501
D
5
Overview of flywheel
E
2
Overview of injection pump/controller
F
0
Overview of air compressor
G
1
Special equipment such as engine-dependent auxiliary output drive
Assembly date
Order of assembly (progress number on day of assembly)
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 8
8/121
7/18/2019
MAN D0836_CR_en
DESIGN AND PRINCIPLE OF OPERATION
The common rail engines are liquid-cooled, 4-stroke in-line engines
In contrast to the other designs, the 240 kW / 326 BHP engine (LF44)
with exhaust gas turbocharger and air/air charge air cooling.
has an external exhaust gas recirculation system. The exhaust gas
is cooled by means of a heat exchanger supplied with cooling water.
The engine's omega-shaped combustion chamber is located in the
The amount of exhaust gas is determined by means of a non-return
centre of the piston and is supplied with fuel by a vertically arranged
valve and a blocking valve pneumatically controlled by the engine
injector nozzle.
characteristic.
The other engine variants such as the LOH/LUH have internal
exhaust gas recirculation, which is defined by the camshaft control
times.
.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 9
9/121
7/18/2019
MAN D0836_CR_en
ENGINE SPECIFICATIONS
D0836 LFL 41 Euro 3
Working principle
4-stroke turbodiesel with charge air cooler
Number of cylinders/Design
Combustion process
6/vertical in line
7-jet direct injection
Direction of rotation viewed from flywheel end
Number of valves per cylinder
Bore/Stroke in mm
Capacity in litres
Compression
Max. ignition pressure in bar
Rated power kW/BHP at speed rpm
Ignition sequence
Position of cylinder 1
Rated speed rpm
Max. torque Nm at rpm
left
4
108/125
6.871
18:1
160
206/280 at 2400
1-5-3-6-2-4
fan side
2400
1100 at 1200-1750
K value (m –1)
CO (G/KWH)
0.410
HC (g/KWh)
0.070
NOX (G/KWH)
4.960
600 rpm ± 50
Idle speed
Max. cut-off speed rpm
Valve clearance with engine cold
ca. 2640
IV 0.50/EV 0.50 mm
EVB clearance with engine cold
0.35 mm
Compression pressure
26 - 30 bar
Permissible pressure diff. between ind. cylinders
max. 4 bar
Coolant
Oil quantity min/max.
Fuel system
Cold start capability with/without glow plug
Weight (dry)
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
1.3
21/26 L
Bosch Common Rail
15/-32°C
598 kg
Page 10
10/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 11
11/121
7/18/2019
MAN D0836_CR_en
D0836 LFL 44 EURO 3
Working principle
4-stroke turbodiesel with charge air cooler
Number of cylinders/Design
Combustion process
6/vertical in line
7-jet direct injection
Direction of rotation viewed from flywheel end
Number of valves per cylinder
Bore/Stroke in mm
Capacity in litres
Compression
Max. ignition pressure in bar
Rated power kW/BHP at speed rpm
Ignition sequence
Position of cylinder 1
Rated speed rpm
Max. torque Nm at rpm
left
4
108/125
K value (m –1)
CO (G/KWH)
0.560
HC (g/KWh)
0.060
NOX (G/KWH)
4.090
Idle speed
Valve clearance with engine cold
18:1
EVB clearance with engine cold
240/326 at 2400
1-5-3-6-2-4
fan side
2400
1200 Nm at 1200-1800
ca. 2640
IV 0.50/EV 0.50 mm
0.35 mm
Compression pressure
26 - 30 bar
Permissible pressure diff. between ind. cylinders
max. 4 bar
Coolant
Oil quantity min/max.
Fuel system
Cold start capability with/without glow plug
Weight (dry)
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
600 rpm ± 50
Max. cut-off speed rpm
6.871
160
1.2
21/26 L
Bosch Common Rail
–15/-32°C
618 kg
Page 12
12/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 13
13/121
7/18/2019
MAN D0836_CR_en
D0836 LOH 41
K value (m –1)
Working principle
4-stroke turbodiesel with charge air cooler
6/vertical in line
Number of cylinders/Design
Combustion process
7-jet direct injection
Direction of rotation viewed from flywheel end
Number of valves per cylinder
Bore/Stroke in mm
Capacity in litres
left
4
108/125
6.871
Compression
18:1
Max. ignition pressure in bar
160
Rated power kW/BHP at speed rpm
Ignition sequence
Position of cylinder 1
Rated speed rpm
Max. torque Nm at rpm
176/240 at 2400
1-5-3-6-2-4
fan side
2400
925 at 1200-1800
CO (G/KWH)
HC (g/KWh)
NOX (G/KWH)
Max. cut-off speed rpm
Valve clearance with engine cold
ca. 2640
IV 0.50/EV 0.50 mm
EVB clearance with engine cold
0.35 mm
Compression pressure
26 - 30 bar
Permissible pressure diff. between ind. cylinders
max. 4 bar
Coolant
Oil quantity min/max
Fuel system
21/26 L
Bosch Common Rail
Cold start capability with/without glow plug down to –15/-32°C
Weight (dry)
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
600 rpm ± 50
Idle speed
ca. 595 kg
Page 14
14/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 15
15/121
7/18/2019
MAN D0836_CR_en
D0836 LOH 40
Working principle
4-stroke turbodiesel with charge air cooler
6/vertical in line
Number of cylinders/Design
Combustion process
7-jet direct injection
Direction of rotation viewed from flywheel end
Number of valves per cylinder
Bore/Stroke in mm
Capacity in litres
left
4
108/125
6.871
K value (m –1)
CO (G/KWH)
HC (g/KWh)
NOX (G/KWH)
600 rpm ± 50
Idle speed
Max. cut-off speed rpm
Valve clearance with engine cold
ca. 2640
IV 0.50/EV 0.50 mm
Compression
18:1
EVB clearance with engine cold
Max. ignition pressure in bar
160
Compression pressure
26 - 30 bar
Permissible pressure diff. between ind. cylinders
max. 4 bar
Rated power kW/BHP at speed rpm
Ignition sequence
Position of cylinder 1
Rated speed rpm
Max. torque Nm at rpm
206/280 at 2400
1-5-3-6-2-4
fan side
2400
1100 at 1200-1750
Coolant
Oil quantity min/max.
Fuel system
21/26 L
Bosch Common Rail
Cold start capability with/without glow plug down to –15/-32°C
Weight (dry)
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
0.35 mm
ca. 600 kg
Page 16
16/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 17
17/121
7/18/2019
MAN D0836_CR_en
D0836 LUH 41
Working principle
4-stroke turbodiesel with charge air cooler
6/vertical in line
Number of cylinders/Design
Combustion process
7-jet direct injection
Direction of rotation viewed from flywheel end
Number of valves per cylinder
Bore/Stroke in mm
Capacity in litres
left
4
108/125
6.871
K value (m –1)
CO (G/KWH)
HC (g/KWh)
NOX (G/KWH)
600 rpm ± 50
Idle speed
Max. cut-off speed rpm
Valve clearance with engine cold
ca. 2640
IV 0.50/EV 0.50 mm
Compression
18:1
EVB clearance with engine cold
Max. ignition pressure in bar
160
Compression pressure
26 - 30 bar
Permissible pressure diff. between ind. cylinders
max. 4 bar
Rated power kW/BHP at speed rpm
Ignition sequence
Position of cylinder 1
Rated speed rpm
Max. torque Nm at rpm
176/240 at 2400
1-5-3-6-2-4
fan side
2400
925 at 1200-1800
Coolant
Oil quantity min/max
Fuel system
21/26 L
Bosch Common Rail
Cold start capability with/without glow plug down to –15/-32°C
Weight (dry)
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
0.35 mm
ca. 640 kg
Page 18
18/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 19
19/121
7/18/2019
MAN D0836_CR_en
D0836 LUH 40
Working principle
4-stroke turbodiesel with charge air cooler
6/vertical in line
Number of cylinders/Design
Combustion process
7-jet direct injection
Direction of rotation viewed from flywheel end
Number of valves per cylinder
Bore/Stroke in mm
Capacity in litres
left
4
108/125
6.871
K value (m –1)
CO (G/KWH)
HC (g/KWh)
NOX (G/KWH)
600 rpm ± 50
Idle speed
Max. cut-off speed rpm
Valve clearance with engine cold
ca. 2640
IV 0.50/EV 0.50 mm
Compression
18:1
EVB clearance with engine cold
Max. ignition pressure in bar
160
Compression pressure
26 - 30 bar
Permissible pressure diff. between ind. cylinders
max. 4 bar
Rated power kW/BHP at speed rpm
Ignition sequence
Position of cylinder 1
Rated speed rpm
Max. torque Nm at rpm
206/280 at 2400
1-5-3-6-2-4
fan side
2400
1100 at 1200-1750
Coolant
Oil quantity min/max.
Fuel system
21/26 L
Bosch Common Rail
Cold start capability with/without glow plug down to –15/-32°C
Weight (dry)
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
0.35 mm
ca. 640 kg
Page 20
20/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 21
21/121
7/18/2019
MAN D0836_CR_en
CRANKCASE
The new crankcase is cast in one piece together with the cylinder
Re-machining the crankcase sealing surfaces:
block from cast iron alloy.
For all engines, three re-machining stages are intended for the
cylinder head joint face.
6 cooling water channels drilled between the cylinders guarantee
Normal dimension A = 321.97 - 322.01 mm
0.0 mm
Stage 1 = 321.77 - 321.80 mm
- 0.2 mm
Stage 2 = 321.57 - 321.60 mm
- 0.4 mm
Stage 3 = 321.37 - 321.40 mm
- 0.6 mm
excellent heat dissipation and a uniform temperature distribution at
the surface of the cylinders.
High rigidity and lower noise emissions are achieved by providing
appropriate ribs on the new aluminium intermediate plate.
Surface roughness of crankcase sealing surface 16 m
The crankcase ventilation is designed as a closed system, i.e. the
B
Main bearing bolts 115 Nm + 90o+10° (do not reuse)
blow-by is fed back to the engine combustion via a v alve with integral
C
Dry cylinder liner
oil mist separator.
D
Flywheel bolts 100 Nm + 90o+10°
(do not reuse)
The pistons run directly in the crankcase where optimum conditions
with regard to resistance to wear and oil consumption are achieved
due to the ceramic honing of the cylinder surfaces.
Note:
Version-dependent (with and without cylinder liners)
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 22
22/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 23
23/121
7/18/2019
MAN D0836_CR_en
CYLINDER LINERS
1. Cylinder liners (slip fit)
"A"
2. Fitting clearances
Normal size
111.490 - 111.535 mm
Clearance between crankcase bore and liners
Rep. stage + 0.5 mm
111.995 - 112.035 mm
Outside diameter (A-E)
0.01 - 0.03 mm
"B"
Crankcase collar diameter
"D"
Collar depth
4.040 - 4.060 mm
"E"
Normal size
111.475 - 111.490 mm
3. Liner projection
"F"
1st Rep. stage
Collar diameter
111.975 – 111.990 mm
115.470 – 115.880 mm
Check amount by which liner projects from crankcase, (measure at
"G"
Inside diameter
108.000 – 108.022 mm
116.00 - 116.10 mm
Wear
"H"
Overall height
At the collar (B-F) 0.12 - 0.36 mm
4 points with clock gauge)
0.150 mm
"D"
Collar depth 4.04 - 4.06 mm
216.700 - 217.000 mm
"C"
Depth of collar recess
"I"
Collar projection
4.00 - 4.03 mm
0.01 - 0.06 mm
NOTE:
Note:
Do not use grease or engine oil when fitting the lining.
ONLY MOLYCODEPOWDER
The collar must sit solidly on the seat. Clean before fitting! The liner
collar must not bear against the outside diameter.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 24
24/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 25
25/121
7/18/2019
MAN D0836_CR_en
CRANKSHAFT
The crankshaft with the counterweights is drop-forged in one piece.
The main and big end bearing journals are induction hardened.
Crankshaft journal diameter
Crankshaft - main bearing internal Ø
STD 76.81 - 77.00 mm
They can be reground 4 times without re-hardening. The thrust
Radial play
0.04 –0.10mm
bearing is situated between cylinders 3 and 4 in all cases .
Crankshaft axial play
0.15 – 0.28 mm
STD 77.04 – 77.08 mm
determined by the axial thrust washers C fitted to the 4th main
A vibration damper is fixed to the front end of the crankshaft. This
bearing (one repair stage possible)
reduces the torsional amplitude and thus the loading on the
crankshaft due to rotational vibration.
o
A
100 Nm + 90
Flywheel angle bolt.
(Note different lengths! No WVW)
B
Vibration damper (no WVW)
150 Nm + 90o
D
Main bearing spread (Miba)
0.60 – 1.60 mm
(Glyco)
0.15 – 0.50 mm
N1 and N2 designs
Even in serial production there are two sizes for big end and
crankshaft bearings and for tappet bores. Colour marking is used for
any other machining stage; every other fitting stage must be
indicated on the nameplate and on the crankshaft.
N
= Normal size
N1
= 0.1 mm dimensional variation
P
= Crankshaft, big end bearing N1
H
= Crankshaft, main bearing N1
S
= Tappet bore N1
E
V-belt pulley with v ibration damper (vulcanised rubber insert)
F
Loctite 574TB sealant for crankshaft gear
G
I
115 Nm + 90
Main bearing bolts
Sealing rings (PTFE). Fit in dry condition only.
X
Fit axial discs with oil pockets facing the crankshaft
o
.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 26
26/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 27
27/121
7/18/2019
MAN D0836_CR_en
CRANKSHAFT SEALING RINGS
Front crankshaft sealing ring
F Rear crankshaft sealing ring (flywheel side)
Assembly
A Preliminary assembly
Fit new crankshaft sealing ring 7 with transport sleeve to adapter
Fit new crankshaft sealing ring 2 with transport sleeve to adapter 4
from special toolkit.
from special toolkit.
Slide crankshaft sealing ring 7 onto adapter and remove transport
Slide crankshaft sealing ring 1 onto adapter and remove transport
sleeve.
sleeve.
Slide press-on sleeve 8 over adapter and screw to threaded spindle
9.
B Fit crankshaft sealing ring
Press shaft sealing ring against front timing gear cover as far as the
Slide press-on sleeve 5 over adapter and screw to threaded spindle
stop using the press-on sleeve.
6.
Press shaft sealing ring against flywheel cover as far as the stop
Press-on tool 80.99606-6030
using the press-on sleeve.
Extractor 80.99606.6011
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 28
28/121
7/18/2019
MAN D0836_CR_en
D
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
F
Page 29
29/121
7/18/2019
MAN D0836_CR_en
TIMING GEAR HOUSING
Removing timing gear cover
Remove fixing bolts from timing gear housing.
Remove timing gear cover fixing screws,
Remove timing gear housing seal 1 from engine block.
remove timing gear cover, and remove front seal 3
from gear casing 4.
Assembly is carried out in reverse order.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 30
30/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 31
31/121
7/18/2019
MAN D0836_CR_en
CONNECTING ROD
The connecting rods are precision drop-forged and separated at the
big end by CRACKING . The separation joint is produced by means
Fitting dimensions
of fracturing (cracking). The small end is trapezoidal in shape. The
Big end bearing journal (normal size) :.... 69.981 – 70.000 mm
Big end bearing spread C(Miba): ....................... 74.5 – 76.0 mm
Big end bearing radial play:............................ 0.026 – 0.088 mm
Big end bearing axial play:............................. 0.120 – 0.259 mm
Hole spacing: ....................................................... 196 0.02 mm
Gudgeon pin bearing (internal) :.....42mm +0.050 + 0.066 mm
Connecting rod weight difference per engine set:
max. 50g
topmost of the two connecting rod bearing shells is made of highly
wear-resistant sputter bearing metal.
Measuring the connecting rod bearings
The measuring instrument is used to measure the bearing hole for
the big end bearing shells in the fitted state in directions 1, 2 and 3
and in measuring planes a and b.
Bearing shells with bearing holes within the tolerance limits can be
reused. If the dimensions are outside the tolerance limits, the
Tightening torque for connecting rod bolts:
Md ....................................................... 50 Nm + 10 plus 90° +10°
Connecting rod bolts M 11x1.5 x60 Torx E14
Connecting rod bolts must not be reused
bearings must be replaced.
The connecting rod and the connecting rod cap are marked together
at the side next to the break point.
NOTE:
Top bearing shell is identified with TOP (B) or red coloured dot on the
side. (Hardened supporting shell).
Note:
Do not stand the connecting rod or the connecting rod cap on
the break point. Damage (change) to the joint can cause damage
to the connecting rod.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 32
32/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 33
33/121
7/18/2019
MAN D0836_CR_en
PISTONS
3-ring (cut back) pistons made from special cast aluminium are used
A: Piston diameter: ................................ 107.791 – 107.800 mm
with a cast-in ring carrier for the top piston ring. The combustion area
B: Measure piston diameter 17 mm above bottom of piston.
is slightly drawn in, stepped and omega-shaped. Valve pockets are
C: Compression height (standard):....................... 63.9 – 64 mm
provided on the crown of the piston on the inlet and exhaust sides. To
D: Piston projection / crankcase edge: .......... 0.093 – 0.391 mm
relieve the thermal stress, the pistons for the D0836 LF44 engine are
manufactured with a cast-in cooling channel and cooled by means of a
Piston ring height / end clearance
jet of oil from the oil spray nozzle.
The flow cross-section of the oil spray nozzles has been matched to
E:
Compression
ring
double-sided
trap.
ring
Height
End clearance
4.00 mm
0.30 to 0.55 mm
Height
End clearance
2.50 – 2.52 mm
0.40 to 0.65 mm
Height
End clearance
2.97 – 3.00 mm
0.30 to 0.60 mm
the new piston cooling channel. The oil spray nozzle is controlled by
means of a pressure control valve in order to ensure adequate piston
F: Sealing ring
taper-faced ring
cooling.
NOTE:
G: Oil scraper ring
bevelled ring
Difference in piston weight per engine set max. 40 g.
Note:
Rings:
Engine D0836 LF44 (326 BHP) with cooling channel pistons
The sealing rings comprise a double-sided trapezoidal ring and a
Engine D0836 LF41 (280 BHP) without cooling channel pistons
taper faced ring. The bevelled spring-loaded ring is used as an oil
scraper ring.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 34
34/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 35
35/121
7/18/2019
MAN D0836_CR_en
CAMSHAFT
The forged camshafts are arranged in the crankcase on the exhaust
side. In the 6-cylinder engines, the camshaft is mounted in 7 leadbronze bushes. The camshafts for external and internal exhaust
gas recirculation differ from one another with respect to the different
"1" Camshaft (external or internal exhaust gas recirculation
design)
"2" Guide pin
"3" Thrust washer
valve timings.
"4" Camshaft gear with 7 reference marks for EDC ECU
The camshaft gear is designed with 7 reference marks, 2 of which
"5" Collar screw, spectacle flange
23 Nm
are considerably closer together than the others.
"7" Collar screw, camshaft gear
65 Nm
These are used by the EDC control unit to detect the first cylinder.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 36
36/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 37
37/121
7/18/2019
MAN D0836_CR_en
Checking camshaft axial play
NOTE:
Check camshaft axial play with clock gauge.
The notch 1 on the camshaft bearing bush must point to the fan side.
The oil holes 2 in bearings 1, 3, 5 must coincide with the oil feed
Camshaft axial play "C" .....................................0.14 – 0.27 mm
holes in the housing. All other bearings are offset with respect to the
Thickness of axial thrust washer "A"..................4.83 – 4.86 mm
holes (no oil feed).
Camshaft bushes  .................................. 51.000 – 51.030 mm
Camshaft bearing diameter........................ 50.910 – 50.940 mm
Radial play ..................................................... 0.060 – 0.120 mm
"B" Camshaft flange bolts M10x38x1.25...........................65Nm
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 38
38/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 39
39/121
7/18/2019
MAN D0836_CR_en
VALVE TIMINGS
The valve timings are checked with the specified valve clearance.
"A": Valve timings: Engine D 0834 external exhaust gas
recirculation
"A": Valve timings: Engine D 0836 external exhaust gas
Inlet opens
recirculation
Inlet opens
D 0834
6°
before TDC
Inlet closes D 0834
32°
after BDC
Exhaust opens
D 0834
63°
before BDC
Exhaust closes
D 0834
13°
after
D 0836
18°
before TDC
Inlet closes D 0836
32°
after BDC
Exhaust opens
D 0836
63°
before BDC
"B": Valve timings: Engine D 0834 internal exhaust gas
Exhaust closes
D 0836
29°
after
recirculation
TDC
Exhaust closes
"B": Valve timings: Engine D 0836 internal exhaust gas
recirculation
Inlet opens
D 0836
18°
before TDC
Inlet closes D 0836
Exhaust opens
D 0836
32°
63°
after BDC
before BDC
Exhaust closes
1°
before TDC
D 0836
59°
after
TDC
Example: Timing diagram
1
Direction of engine rotation
2
Inlet opens
3
Exhaust closes
4
Inlet opening time
5
6
7
8
9
Centre of inlet cam
Exhaust opens
Exhaust closes
Exhaust opening time
Centre of exhaust cam
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
D 0834
TDC
Page 40
40/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 41
41/121
7/18/2019
MAN D0836_CR_en
ENGINE TIMING
On assembly, the mark on crankshaft gear "A" must coincide with
Tightening torques:
the mark on crankshaft gear "B" identified by " -  - ".
A
Crankshaft gear..........................Z = 32..... 150 Nm + 90°
B
Camshaft gear............................Z = 64 ................ 65 Nm
C
Compressor drive gear...............Z = 27 ...........................
D
Intermediate gear ....................... Z =40................ 115 Nm
E
Intermediate gear .......................Z = 31 ................. 22Nm
F
CR high-pressure pump .............Z = 24
G
Oil pump drive gear. ................... Z =18.................. 30 Nm
H
Water pump fitting
Note:
Intermediate gear "D" is mounted with the VP 44 radial injection
pump as on engine D0834/36.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 42
42/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 43
43/121
7/18/2019
MAN D0836_CR_en
ENGINE OIL CIRCULATION
Forced feed lubrication:
Engine oil pressure
The forced feed lubrication system feeds the crankshaft, big end and
camshaft
bearings.
The
valve
drive,
intermediate
gear,
air
Idle speed 600 rpm ....................................................... > 1.0 bar
Rated speed 2400 rpm..................................................> 4.0 bar
compressor and exhaust gas turbocharger are supplied with
lubricating oil.
The oil pressure must be checked when the engine is warm.
The gear oil pump sits in the spur gear housing. The gears are fitted
in the pump housing and in the spur gear housing. The oil pressure
"A"
Oil pressure control valve
control valve sits in the main channel and serves to relieve the load
Opening pressure........................ 5.0 – 6.0 bar
on the oil pump after a cold start at low ambient temperatures.
The oil filter and plate oil cooler are physically combined in the oil
"B"
module. Recyclable paper filters enable the oil filter to be disposed of
Oil filter bypass valve
Opening pressure........................ 2.5 ± 0.5 bar
in a maintenance friendly and environmentally friendly manner.
The piston crown is cooled by the valve-controlled oil spray nozzle,
"C" Oil filter bottom valve (drainage protection)
which sprays into the piston ring channel or onto the piston crown.
Opening pressure........................ 0.2 ± 0.1 bar
Engine oil M 3477 Euro 4 – M 3277 Euro 3
Oil pressure switch B 104:
The only engine oils that are approved are those, which have been
Wire (0.75mm2)
60155 Pin 1 to EDC A40
tested to and comply with works standard M 3477/3277.
Wire (0.75mm2)
60158 Pin 2 to EDC A37
Wire (0.75mm2)
60137 Pin 3 to EDC A20
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 44
44/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 45
45/121
7/18/2019
MAN D0836_CR_en
Oil pump:
1
FIXING NUT
NOTE:
2
DRIVE GEAR
Slide oil pump drive gear "4" (internal taper free from grease) onto
3
OIL PUMP GEAR
grease-free taper of drive gear.
4
OIL PUMP GEAR
Oil pump gears must not be fitted dry
5
OIL PUMP HOUSING
(indicated by a note on gears 3/4)
6
FIXING BOLT M24X1.5 60NM
7
SEALING RING
Tightening torques:
8
COMPRESSION SPRING
Oil pump drive gear nut "1" M12x1.5..................................... 30 Nm
9
PISTON
10
INTERMEDIATE PLATE
Checking the gap:
Gap = Housing depth minus Gear height
ENGINE OIL PRESSURE CONTROL VALVE:
Measure gear height at different positions
WITH 9 PISTON - 8 SPRING 7 SEALING RING
Measure housing depth:
Housing depth
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
25.000 – 25.033 mm
Page 46
46/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 47
47/121
7/18/2019
MAN D0836_CR_en
Oil filter module
The oil module 6 combines the oil filter 4 and oil cooler in one
housing. The filter is designed as a recyclable paper filter. The
Oil filter bypass valve.............................................. 2.5 ± 0.5 bar
Oil filter bottom valve (drainage protection)............. 0.2 ± 0.1 bar
heated engine oil is cooled in a heat exchanger 9 by approximately
Oil return blocking valve............................................................ 7
0
15 C.
Tightening torque, filter cover 2.........................................25 Nm
Fixing bolts to engine ........................................................22 Nm
Oil pressure switch 5 .........................................................50 Nm
Oil filter cover spanner 1 ..................................... 80.99606.0581
Oil module seal 8
Replace sealing rings 3/10 when changing filter
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 48
48/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 49
49/121
7/18/2019
MAN D0836_CR_en
Oil spray nozzle for piston crown cooling:
NOTE:
Oil spray nozzle pressure valve:
Ensure that the adjusting ball in the body of the oil spray nozzle
locates in the hole provided.
1
Valve remains closed until.................................... 1.5 +– 0.1 bar
Valve fully open .................................................... 2.0 +– 0.1 bar
Bent oil spray nozzles must not be straightened!
2
Oil pressure valve begins to open .......................... 1.4 – 1.6 bar
3
Oil pressure valve fully open................................... 1.9 – 2.1 bar
Checking oil spray nozzles
Check whether the valve spring still pushes the valve piston onto the
valve seat, otherwise change oil spray nozzle valve.
Tightening torques:
Oil spray nozzle pressure valve M12 ........................................ 40 Nm
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 50
50/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 51
51/121
7/18/2019
MAN D0836_CR_en
BELT DRIVE
The V-belt is no longer driven from the belt pulley on the crankshaft
vibration damper but via the belt drive shaft, which is connected to
A .........Left-hand threaded bolt M16x1.5x45-8.8LH 100 Nm+90°
B .........Belt pulley
the compressor drive gear. The belt drive (E) is connected to the
compressor drive gear (D) by means of the cross-shaped disc ( G)
and does not require adjustment. The belt pulley is fixed to the drive
shaft by means of a screw ( A) with a left-hand thread.
C .........Fixing bolt M10x35-8.8
45 Nm
D .........Compressor gear
E..........Drive housing
The V-belt tensioner (1, 2) works automatically and needs no
adjustment. To loosen the belt, turn hexagonal bolt (1) anticlockwise
F ..........O-ring
and remove belt.
G .........Cross-shaped disc
Note:
The central bolt (A) for the belt pulley (B) has a left-hand thread.
H .........Belt tensioner for alternator and water pump
I ...........Belt tensioner for optional extras, e.g. air-conditioning
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 52
52/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 53
53/121
7/18/2019
MAN D0836_CR_en
CYLINDER HEAD
The channelling in the cylinder head of the D 0836 Euro 4 engine is
"1" Height of cylinder head
different from that of the Euro 3 engine. In order to withstand the high
Overall height "A"............................. 109.85 –110.15 mm
peak combustion pressures, the engines have just one continuous
Minimum size.................................... 109.35 –110.05 mm
cylinder head for all cylinders.
"2" Valve seat angle
The cylinder head is made from cast iron alloy with cast-in inlet and
Exhaust valve ................................................................ 90o
exhaust channels. The cylinder head is fixed with 4 equally
Inlet valve .................................................................... 120o
distributed angle bolts per cylinder. (24 in total). The exhaust and
inlet valve seating rings are shrunk in place, and the v alve guides are
pressed in. The valve star is slightly offset.
"3" Valve recess distance
Exhaust "A" .............................................. 0.60 – 0.90 mm
Inlet "B" .................................................... 0.30 – 0.60 mm
The sealing surface of the cylinder head "A" can be re-machined
(maximum 0.5 mm)
"4" Valve guides
A thicker copper washer must then be used for the injector
Exhaust valve guide recess .... 22.70 – 23.10 –-(-0.40 mm)
(51.98701.0093).
Inlet valve guide recess ............20.70 – 21.10 –(-0.40 mm)
The core hole closures are fitted with Loctite 648.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 54
54/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 55
55/121
7/18/2019
MAN D0836_CR_en
CYLINDER HEAD FIXING
TIGHTENING/CHECKING CYLINDER HEAD BOLTS:
NOTE:
Tightening torques and torsion angle:
Engine cylinder head bolts must not be reused once they have been
loosened.
Tightening sequence following a repair:
When repairs are carried out, as a basic principle all cylinder head
Align, and pre-tighten to 10 Nm
bolts M 14 x 2 (E18) must be replaced.
1st tightening stage
80 Nm
NOTE:
2nd tightening stage
3rd tightening stage
150 Nm
90°
The combustion chamber is sealed by means of multi-layer steel
4th tightening stage
90°
gaskets with enhanced sealing quality, and re-tightening is not
5th final tightening stage
90°
necessary.
Smear contact surface of the cylinder head bolts with Optimol White
No further re-tightening of the cylinder head bolts is required.
T and oil the thread.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 56
56/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 57
57/121
7/18/2019
MAN D0836_CR_en
CHECKING AND ADJUSTING VALVE CLEARANCES
VALVE ADJUSTMENT:
IGNITION SEQUENCE: D 0834 1 - 3 – 4 – 2
IGNITION SEQUENCE: D 0836 1 - 5 – 3 – 6 – 2 – 4
Overlap
Adjustment
=
=
624153
153624

A
Valve clearance, inlet valve
0.50 mm

B
Valve clearance, exhaust valve
0.50 mm

C
Clearance, rocker braking device
0.35 mm
Fixing bolt (cylinder head bolt)
Fixing bolt, bottom cable shaft M6x1 (8.8)
Lock nut, valve adjustment screw M10x1 (8.8)
1
Valve adjustment screw, inlet valve
2
Feeler gauge 0.50 mm
3
Valve bridge, inlet valve
4
Valve bridge, exhaust valve
5
Adjusting nut, exhaust valve
6
Adjusting screw, exhaust valve
7
Adjusting screw EVB
8
Lock nut EVB
9
Feeler gauge 0.35 mm
9 Nm
9 Nm
40 Nm
The valve clearances are adjusted with the engine cold (T < 500)
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 58
58/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 59
59/121
7/18/2019
MAN D0836_CR_en
Removing an injector:
Fitting an injector:
Note:
1 Do not remove the injector from the box until immediately

Before removing the injector, always remove the appropriate
before fitting.
pressure pipe support first.
2 Remove protective cover from injector hole in cylinder head.

Only remove one injector at a time.
3 Always fit injector together with pressure flange.

Remove injector with pressure flange and seal.

Immediately seal injector hole in cylinder head with a
4 Fit new O-ring and new Cu gasket to injector.
protective cover.
5 Slide pressure flange onto injector.

Immediately seal injector nozzle with a protective cover.
6 Fit injector together with gasket and pressure flange into

Remove injector O-ring from above and place the injector in a
box for safe keeping.
(Pressure flange cannot be fitted retrospectively).
cylinder head.
7 Push injector with pressure flange completely into cylinder
head.
8 Align pressure pipe connection hole in injector channel
pressure pipe support in cylinder head.
Tighten fixing screw and spherical washer slightly to allow for
later adjustment.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 60
60/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 61
61/121
7/18/2019
MAN D0836_CR_en
TIGHTENING INJECTOR ON CYLINDER HEAD
1.
High-pressure pipe
2.
Connector
3.
Sleeve nut
4.
Leakage oil channel
A
Pre-tighten Allen screw to 2 Nm
5.
Pressure pipe with filter and anti-rotation locking device
B
Pre-tighten pressure screw to 10 Nm
6.
Copper washer
C
Tighten Allen screw finally to 30 Nm
7.
O-ring
D
Tighten pressure screw finally to 55 Nm
8.
9.
Electrical connection
Injector
E
F
High-pressure pipe sleeve nut 10 Nm + 30
Tighten electrical connector to 1.5 Nm
10.
Anti-rotation locking device for sword connector
Injector tightening procedure:
0
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 62
62/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 63
63/121
7/18/2019
MAN D0836_CR_en
ROCKER MECHANISM
Technical data:
1
Rocker, exhaust valve
2
Valve adjustment screw
Fixing bolts (cylinder head cover)
3
Thrust washer
Retaining screw, rocker shaft (8) M8x50-8.8
22 Nm
4
Compression spring
Fixing screw, rocker mechanism M8x85-8.8
22 Nm
5
Thrust washer
6
Valve adjustment screw
7
Rocker, inlet valve
8
Retaining screw, rocker shaft
9
Rocker shaft
10
Rocker block
11
Adjusting screw EVB
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
9 Nm
Page 64
64/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 65
65/121
7/18/2019
MAN D0836_CR_en
EXHAUST VALVE BRAKE
All D 0836LF engines are fitted with the conventional EVB. The
If the exhaust brake valve is closed, pressure waves build up in the
braking effect is increased by ca. 60% compared with a conventional
exhaust manifold, which briefly re-open the exhaust valve, i.e. the
engine brake.
exhaust valve is opened again briefly every time it closes.
A hydraulic piston, to which engine oil pressure is applied, is located
As the piston is under oil pressure, it is pushed in the same direction
in the exhaust valve bridge. The oil pressure can dissipate again due
as the briefly opening valve, but cannot return, as the counter-
to a relief hole. A counter-support is located above the valve bridge
support closes the relief hole and the non-return valve closes the oil
with an adjustment screw, which seals the relief hole when the
exhaust valve is closed. When the camshaft opens the valve, the
feed hole.
The exhaust valve therefore remains slightly open during the
relief hole is opened and the oil pressure in front of the piston can
compression stroke and the subsequent expansion cycle. This
dissipate.
negates the compression work of the piston, which would otherwise
have driven the crankshaft. The braking power of the engine
increases.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 66
66/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 67
67/121
7/18/2019
MAN D0836_CR_en
EVB - SERVICE INFORMATION / EXHAUST BUTTERFLY VALVE UNCONTROLLED
Inside the exhaust butterfly valve is a torsion bar spring to control the
Gap:
exhaust counterpressure.
It is therefore important that the engine braking valve is always
If the initial tension is too large (gap too large), the exhaust valves
closed with the specified initial tension.
will be too highly stressed thermally and may overheat or burn out.
If the initial tension is too small (gap too small), a corresponding loss
of engine braking power may occur.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 68
68/121
7/18/2019
MAN D0836_CR_en
Adjusting the engine braking valve gap:
The gap is checked and adjusted with the actuating cylinder removed.
Measure the gap with the actuating cylinder
If the gap is too large, reduce the initial
If the gap is too small, increase the initial
removed after closing the engine braking
tension of the torsion bar spring.
tension of the torsion bar spring.
valve by hand.
Open the valve by hand, and push the torsion
Place an object between the " closed" stop
bar spring carefully against the "open" stop.
and the valve lever, close the valve by hand,
and push the torsion bar spring carefully
against the stop.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 69
69/121
7/18/2019
MAN D0836_CR_en
INLET MANIFOLD
Inlet manifold with return pipe:
The return pipe for the injectors is integrated within the inlet manifold,
Inlet manifold gasket:
and the two channels (inlet, return) are sealed with a steel gasket.
C
Intake air
The gaskets are discontinuous between the individual channels.
D
Discharge opening in the event of leaks
See repair manual A 20 Page 6,105
E
Injector fuel return
A
B
Inlet manifold with integral injector return pipe
Common return connector
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 70
70/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 71
71/121
7/18/2019
MAN D0836_CR_en
EXHAUST GAS RECIRCULATION
In order to obtain favourable economy, high utilisation of energy and
The hot exhaust gases are fed to the EGR module by means of the
low fuel consumption in the Euro 3/4 Common Rail engines, the
EGR valve connecting pipes. The exhaust gases flow through the
D0836.. engines are equipped with an internal or external controlled
double-flow stainless steel heat exchanger in the EGR module. The
exhaust gas recirculation system (EGR).
exhaust gas is cooled in the EGR module from ca. 700°C to less than
200°C (in the Euro 3) by means of cooling water (the temperatures
With exhaust gas recirculation, some of the burned gases are fed
in the Euro 4 are even lower).
back to the cylinder (ca. 10% Euro 3 and up to ca. 20%
The EGR butterfly valve on the hot side is actuated by a compressed
Euro 4 ). This results in lower combustion temperatures and thus
air cylinder. The solenoid valve and a reed switch are integrated
lower NOx emissions.
within the compressed air cylinder.
A
Air filter
1 Inlet
Internal EGR:
B/5
Charge air cooler
2 Exhaust gas outlet
The internal exhaust gas recirculation is controlled by the valve
C
Engine inlet manifold
3 Waste gate bypass
timings.
to
D
EGR cooler
6 Engine
approximately 10% remains in the cylinder as a result of closing the
E
Peak pressure valves
8 Timing valve
exhaust valve early.
F/4
Electropneumatically controlled blocking valve
G/7
Exhaust butterfly valve
PM Kat (Euro 4 engine)
9 Low-pressure stage
PM
a
(1) from turbocharger
b (2) to atmosphere
c
(3) to waste gate
d Electrical connector
A
residual
amount
of
exhaust
gas
amounting
External EGR:
With external exhaust gas recirculation, the exhaust gas is extracted
from the exhaust manifold and cooled in the EGR module.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 72
72/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 73
73/121
7/18/2019
MAN D0836_CR_en
Components of the exhaust gas recirculation system:
A
Fixing bolt M 8x55-8.8
B
Connecting pipe, inlet manifold - EGR module
C
Cover
D
Peak pressure valves
E
Water outlet EGR cooler
F
EGR module
G
Water inlet EGR cooler
H
Exhaust gas connecting pipe - blocking valve and EGR cooler
Charge air temperature sensor .................. .......................... 45 Nm
I
Exhaust gas inlet to EGR module
Cover for peak pressure valves......... M8x60-8.8.................. 22 Nm
J
Blocking valve EGR module
Cable shaft on EGR module.............. M6x18-8.8.................... 9 Nm
23 Nm
Euro 4 control with infinitely variable adjustment

1 Blocking valve with integral position sensor for feedback
of EGR valve position

2 Proportional valve for control of compressed air in Euro 4
with stepless adjustment
Tightening torques:
EGR control:
Note:
Euro 3 control (black, white)
The EGR module must not be dismantled. It is forbidden to open

Compressed air cylinder for EGR valve electrically
the rear manifold.

actuated by the EDC ECU
Reed contact switch for feedback of EGR valve position to
Adjusting the EGR cylinder:
EDC control unit, Euro 3

Compressed air connection from circuit 4 (10 bar)
Note that the exhaust gas recirculation cylinder is pre-stressed to ca.
4 mm
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 74
74/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 75
75/121
7/18/2019
MAN D0836_CR_en
TURBOCHARGER
Maintenance-free exhaust gas turbocharger, 1-stage charging with
With two-stage charging, the exhaust gas first flows through a small
waste gate
turbocharger (high-pressure stage) and then through a larger
Waste gate opening starts at
Waste gate stroke
1.52 bar
1.1 – 2.6mm
turbocharger (low-pressure stage).
As two turbochargers are available for the whole speed-load range,
the HP (high-pressure) turbine can be made very small. It is
A
Turbocharger, single-stage design
therefore easier for the HP compressor to quickly provide the
B
Seal for oil return pipe
required amount of air during acceleration.
C
Fixing bolt
When there is a high mass flow of exhaust gas, the high-pressure
D
Fixing bolt
turbine is partially bypassed. This keeps the unburned carbon during
acceleration low and avoids overloading the HP turbine.
2-stage charging, via timing valve controlled exhaust gas
The advantages of two-stage charging can be clearly seen in
turbocharger in the D0834 LFL42 151 kW 4-cylinder engine
dynamic operation. Along with the increased amount of air available,
the main factor here is the improved response.
1
Charge air outlet
2
Note:
3
Exhaust gas inlet
Engine oil connector
4
Intake air inlet
The charge pressures are pressures, which are measured after the
The actual charge pressure can be interrogated with MAN_CATS 2.
charge air cooler, and are not equal to the waste gate valve opening
pressure.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 76
76/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 77
77/121
7/18/2019
MAN D0836_CR_en
TWO-STAGE CONTROL VALVE
Design 3/2 control valve (PWM controlled timing valve) 24 Volt
1
From turbocharger
A
Mark-space ratio in %
2
To atmosphere
B
Pressure at connector 3 to waste gate pe(kPa)
3
To waste gate
4
Electrical connector (PWM signal EDC 7) ca. 91 Ohm
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 78 of 121
78/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 79
79/121
7/18/2019
MAN D0836_CR_en
CHARGE PRESSURE CHARACTERISTIC
A
Charge pressure (m bar)
B
Engine speed (rpm)
C
Torque (Nm)
D
Engine torque curve
E
Example of uncontrolled charge pressure.
F
gate.
G
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Example of charge pressure with uncontrolled waste
Charge pressure, controlled waste gate with timing
valve.
Page 80 of 121
80/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 81
81/121
7/18/2019
MAN D0836_CR_en
TURBOCHARGER
Operation of the PM-Kat® system (PM = Particulate Matter):
1.
The PM-Kat is integrated within the normal exhaust housing
2.
The exhaust gas flows through the two identical individual
modules (A, B) inside the unit
3.
In the first stage, nitrogen monoxide NO is oxidised to form
nitrogen dioxide NO2 in the upstream section of the catalytic
Components:

Temperature sensor before the PM Kat

Temperature sensor after the PM Kat

Differential pressure sensor
converter (Platinum converter A)
(2NO +O2 = 2NO2) PM KAT
4.
In the second stage (B), unburned carbon particles are
separated in a sintered metal fleece by the specific formation
of turbulence. (Separator)
5.
The trapped carbon particles are burned with the NO2 formed
in the first stage, and thus converted to gaseous carbon
dioxide CO2.
6.
In this way, the smallest particles are removed and eliminated
from the exhaust gases.(D)
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 82
82/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 83
83/121
7/18/2019
MAN D0836_CR_en
PREVENTION OF ACCIDENTS - COMMON RAIL CLEANLINESS
CAUTION Risk of injury
Jets of fuel can penetrate the skin.
Vaporisation of fuel presents a fire risk.
You should wait for at least one minute before undoing the bolts until
the rail pressure has dissipated.
Check the pressure reduction in the rail with MAN-cats 2 if
necessary.
Never undo the bolts on the high-pressure fuel side of the common
rail system with the engine running (injection pipe from the high-
Caution:
pressure pump to the rail, on the rail, and on the cylinder head to the
Do not touch live parts on the injector electrical connector when the
injector).
engine is running.
Caution:
Risk of injury!
When the engine is running, the pipes are continuously under
high fuel pressure up to 1,600 bar.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 84
84/121
7/18/2019
MAN D0836_CR_en
Working on the CR system:
Cleanliness:
Modern diesel injection components are today made from highprecision parts, which are subjected to extreme loads. Because of
this high-precision engineering, extreme cleanliness must be
observed when carrying out any work on the fuel system.
Dirt particles of more than 0.2 mm can lead to component failure.
Do not use the steam jet to spray directly onto electrical components,
alternatively fit covers
Position the vehicle in a clean part of the workshop where no work,
which could generate dust, is being carried out. (Grinding, welding,
brake repairs, brake and power tests etc.)
It is therefore essential that the measures described below are
observed before starting work:
Before starting work
Avoid air movements (possible generation of dust by starting
engines, workshop ventilation/heating, draughts etc.).
The area around the still sealed fuel system must be cleaned and
dried with compressed air.
Risk of damage due to contamination!
The engine and engine compartment must be cleaned before
working on the clean side of the fuel system (steam jets). When
Protective slee ve set

Set of protective sleeves for fuel connections

Complete set Et. No.
Protective tube for injector Et. No.
81.96002-6005
09.81020-1000

Protective tube for pressure pipe Et. No.
09.81020-1001
doing so, the fuel system must be sealed.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 85
85/121
7/18/2019
MAN D0836_CR_en
During work
RISK OF DAMAGE DUE TO CONTAMINATION!
The use of compressed air for cleaning is not permitted after opening
The connecting openings of all removed parts of the clean-side fuel
system must be sealed immediately with suitable sealing caps.
the clean side fuel system.
Loose dirt must be removed during the assembly work by means of a
This sealing material must be kept packed in a dustproof container
suitable suction device (industrial vacuum cleaner).
until it is used, and must be disposed of after a single use.
The components are then to be stored carefully in a clean, closed
Only undamaged tools may be used (scratched chrome plating).
container.
Materials such as cloths, cardboard or wood may not be used when
removing and fitting components, as these may shed particles and
For these components, never use cleaning or test liquids that have
fibres.
already been used.
If paint should become chipped when undoing connections (possibly
New parts must not be taken out of their original packing until
due to excess painting), then these chips of paint must be carefully
immediately before use.
removed before finally removing the bolt.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 86
86/121
7/18/2019
MAN D0836_CR_en
Bus engine
NOTE:
Risk of damage due to contamination!
Remove injectors:
Before opening the clean-side fuel system:
After removal:
Clean the parts of the engine around pressure connectors, injection
Flush out the injectors with the high-pressure connection hole
pipes, rail and valve cover with compressed air.
pointing downwards using a cleaning fluid
Removed the valve cover and then clean the parts of the engine
Remove pressure pipe c onnectors:
around the pressure connectors, injection pipes and rail once more.
Unscrew pressure pipe connector sleeve nuts, remove pressure pipe
Next slacken only the pressure pipe c onnectors:
connectors and clean injector hole in cylinder head.
Slacken the sleeve nuts on the pressure pipe connectors and
Assembly is carried out in exactly the reverse order.
unscrew by 4 turns.
Lift
the
pressure
pipe
connectors
using
a
special
tool.
Reason: do not remove the pressure pipe connectors completely until
the injectors have been removed so that no dirt can fall into the
injectors from above.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 87
87/121
7/18/2019
MAN D0836_CR_en
COMMON RAIL SYSTEM WITH EDC 7 ENGINE CONTROL UNIT
The CR injection system consists of a quantity-controlled high-
pressure. Other sensors, such as coolant temperature sensor,
pressure pump, which can apply very high fuel pressure to a "rail"
charge air temperature sensor or atmospheric pressure sensor help
storage volume (max. 1600 bar). The rail transmits this pressure to
the engine to adjust optimally to changing ambient conditions.
the "injector" to enable it to inject a fine vapour.
The main feature of the CR system is therefore the decoupling of
A High-pressure
B Low-pressure section
C Fuel tank
D Suction line
E High-pressure pump
F Pressure line
pressure generation and injection from the rail. This pressure-timecontrolled injection system thus overcomes the typical limitation of
G Pre-supply pump
J Rail
H FSC
K Rail pressure sensor
I Pressure limiting valve
L High-pressure line
conventional cam-controlled systems. The increased average
injection pressure and the timing of the injection can be selected
within wide limits independently of the engine operating point.
M Injector
O Camshaft sensor
Q Input signals
R Output signals
P Crankshaft sensor
This is the basis of a combustion process, which achieves excellent
values for exhaust emissions and noise.
Note:
The hydraulic components of the injection system are monitored by
CR engines are not approved for use with RME (biodiesel) for
the control unit, the sensors of which continuously gather data related
the time being
to the engine and vehicle operation. So, for example, the rail
pressure sensor, the control unit and the pressure-controlled highpressure pump form a control loop for producing the required rail
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 88
88/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 89
89/121
7/18/2019
MAN D0836_CR_en
Injection lines:
The injection lines (A) have an outside diameter of 6 mm and are
Note:
The same CR cleanliness specifications apply when changing the
hydraulically pre-stressed and matched in length due to the high line
pressures. They are fixed to the engine using anti-vibration fittings.
filter.
Fuel feed line to CR injector:
The CR injectors vertically mounted in the cylinder head are clamped
CR injector and injection nozzles:
from above by means of a bracket with high-elasticity bolts. 7-jet
The fuel feed line from the injection line to the CR injector is in the
blind-hole nozzles with an opening pressure of 300 bar are fitted. The
form of a pressure pipe, which is c lamped from the outside by means
CR injector is sealed at the bottom by means of a Cu ring, and at the
of a clamping nut. An edge-type filter is integrated within the pressure
top with an O-ring.
pipe. The pressure pipe is arranged at one side of the cylinder head.
This avoids the necessity of opening the fuel side when servicing the
A Fuel tank
B High-pressure pump CP3 fuel distributor
valve drive. The CR injector leakage fuel is fed to a common pipe
C Fuel pump
outside the pressure pipe.
D Fuel filter
E Pre-filter manual pump engine oil filling
Fuel Service Centre (FSC):
The FSC, which has been redesigned for the CR engines, is
mounted on the air distribution pipe and comprises externally
mounted hand pump G, pre-cleaner, main filter, permanent
ventilation and filter heating in one module.
F Proportional valve
H Glow plug
I Pressure limiting valve
J Rail
K Rail pressure sensor
L Injector
M Leakage oil return (overflow valve 1.2 –1.3 bar on Euro3 only)
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 90
90/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 91
91/121
7/18/2019
MAN D0836_CR_en
Fuel system:
A new Fuel Service Centre (FSC) is used in the D08 CR engines.
The conventional glow plug starting system, albeit with a new
The FSC combines the pre-cleaner with the manual pump, main
solenoid valve, is provided as an aid to cold starting.
filter, permanent ventilation and heating element in one unit. A fuel
The gear pump sucks the fuel from the tank and pumps it through the
pressure probe for monitoring the fuel filter is also provided between
fuel filter to the high-pressure pump.
the fuel pump and the FSC. The pre-filter is washable.
Compared with conventional versions, common rail fuel filters are
Note:
very much finer. The filter inserts are fully recyclable.
The system is bled by slackening and operating the hand pump.
Note:
A
Drain screw
When changing the filter, do not suck out deposited dirt but
B
Sealing ring, heating element
allow it to run out through the drain screw.
C
Fuel filter for high-pressure pump
D
Fuel filter seal
E
Pre-filter
F
Sealing ring
H
Filter cover
J
Electrical connector - filter heater and fuel temperature
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 92
92/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 93
93/121
7/18/2019
MAN D0836_CR_en
LOW-PRESSURE SECTION
Components:
The fuel pump must not be dismantled or removed from the highpressure pump.
Fuel transfer pump:
The gear transfer pump sucks the fuel from the tank and pumps it

1 BYPASS VALVE OPENS AT CA. 10-11 BAR
through the FSC to the high-pressure pump.

2 NON-RETURN VALVE F OR BLEEDING THE SYSTEM

3 GEAR PUMP

4 HAND PUMP

A FROM FUEL TANK

B TO FUEL SERVICE CENTRE
All fixed engine fuel lines are designed as PA pipes with easy-to-fit
Raymond plug connectors.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 94
94/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 95
95/121
7/18/2019
MAN D0836_CR_en
HIGH-PRESSURE SECTION
The high-pressure section has the task of producing the high
B
Metering unit (M-Prop.):
pressure required for injection and pumping an adequate quantity of
(Fuel quantity proportional valve) CP 3.4
fuel under all operating conditions. The fuel is pumped from the
The metering unit (M-Prop.) is bolted to the suction side of the
transfer pump (3) via the fuel lines to the FSC, and via the metering
high-pressure pump housing.
unit (1) into the suction chamber of the high-pressure pump.
The metering unit is controlled by means of a PWM signal (pulse
The metering unit is an actuator for controlling the fuel pressure in
width modulated signal).
the high-pressure reservoir of the rail and controls the input pressure
Mark-space ratio 100% No pumping min. input pressure
in the high-pressure pump.
Mark-space ratio 0%
Maximum pumping max. input pressure
A High-pressure pump CP 3.4:
The high-pressure pump must be filled with engine oil (0.04 l) when
C
Max. fuel quantity
the pump is changed or a new one fitted. Tighten the oil filler screw to
D
Min. fuel quantity
18 Nm. New fuel-lubricated version.
E
Trapezoidal slot
Grease the taper of the drive gear when assembling the gear.
The drive gear is fitted to the drive shaft without grease and
tightened to 110 Nm.
Tighten M10 flange bolts ( 2) to 45 Nm.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 96
96/121
7/18/2019
MAN D0836_CR_en
A
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
B
Page 97
97/121
7/18/2019
MAN D0836_CR_en
CR HIGH-PRESSURE PUMP CP3
Unlike conventional diesel engines, the installation of the CR high-
1
Fuel feed from fuel filter
pressure pump requires no adjustments.
2
To rail
3
To tank
The CR pump is driven by the camshaft gear with a ratio of 1:1.67 to
4
To filter
the crankshaft.
5
Return to tank
6
From filter
When the engine is started, the signals from the speed sensor on the
7
To rail
camshaft drive gear and the f lywheel speed sensor are synchronised.
8
Proportional valve
After a few revolutions, the CR high-pressure pump receives the
NOTE:
signal (reference mark signal 1st cylinder) and the engine runs.
The starting process takes somewhat longer with CR engines than
with conventional diesel engines (finding TDC mark).
A
High-pressure section
B
Low-pressure section
C
Engine oil
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 98
98/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 99
99/121
7/18/2019
MAN D0836_CR_en
REMOVING/FITTING HIGH-PRESSURE PUMP
Removing the high-pressure pump:
Remove fuel lines and seal all connectors including high-pressure
pump with plastic plugs.
Note:
Unscrew only one line at a time and immediately seal the connectors
with clean plastic plugs.
Fit special tool (A) to the high-pressure pump (B). Unscrew fixing
bolts and remove high-pressure pump.
Withdraw the high-pressure pump by tilting and turning between the
oil module and the timing gear housing.
Fitting the high-pressure pump:
Insert the high-pressure pump with the new O-rings (one O-ring for
the lubricating oil feed hole and one O-ring for the housing seal)
between the oil module (E) and the timing gear housing, and by
turning and tilting (F) align it with the flange on the timing gear
housing, insert and fit.
Note:
Version 1
Fill high-pressure pump with engine oil (0.04 l).
The engine oil can be added by means of a pipette (C).
Version 2
The latest version of the CP3 high-pressure pump is now fuellubricated.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 100
100/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 101
101/121
7/18/2019
MAN D0836_CR_en
RAIL
The
high-pressure
reservoir
(rail)pressure
has the oscillations
task of storing
fueldue
at
high-pressure.
At the
same time,
that the
occur
to the pumping and injection actions, are damped by the storage
volume.
The pressure in the rail is maintained at an almost constant value
even when using large quantities of fuel. This ensures that the
injection pressure remains constant when the injector is opened.
If
the
pressure
valve
open quickly enough when the
rail
pressure
is limiting
too high,
it is does
forcednot
open.
To force open the pressure limiting valve, the fuel metering unit is
opened and the removal of fuel for injecting is blocked.
The rail pressure increases rapidly until the opening pressure of the
pressure limiting valve is reached. If this forcing action is not
successful, e.g. due to a mechanically sticking pressure limiting
valve, the engine is shut down.
A Two-stage pressure limiting valve:
B Rail pressure sensor
The
two-stage
pressure
limitingvalve
valveand
is mounted
on limiter.
the rail and has
the function
of an
overpressure
a pressure
If the pressure is too high, a drain hole is opened.
Under normal operating conditions, a spring pushes a piston tightly
into the valve seat so that the rail remains closed. Only when the
maximum system pressure is exceeded is the piston pushed open
against the spring by the pressure in the rail.
Pin 1 (60160) –A 61 Rail pressure ground
Pin 2 (60162) –A 80 Rail pressure input (1.01-1.60 Volt)
Pin 3 (60161) –A 43 Rail pressure (4.75-5.25 Volt)
Approximately 30 cm3 of fuel is available in the rail.
Note:
If the rail pressure is too high (1800 bar), the first piston moves and
opens part of the cross-section permanently. The rail pressure is then
held constant at ca. 700-800 bar.
The two-stage pressure limiting valve does not close again until the
engine is stopped. Once the pressure limiting valve has opened, the
second stage remains open as long as the engine is running.
Rail tightening torque 45 Nm
C High-pressure line connector
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 102
102/121
7/18/2019
MAN D0836_CR_en
A
B
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 103
103/121
7/18/2019
MAN D0836_CR_en
INJECTOR
The CR injectors vertically mounted in the cylinder are clamped from
above by means of a bracket. 7-jet blind-hole nozzles with an
Components:
1
Jet needle
2
High-pressure connector
opening pressure of 300 bar are fitted.
3
Coil
4
Valve ball
5
Electrical connector
6
Fuel return
7
Feed throttle
8
Drain throttle
9
Drain valve ball
The EDC 7 control unit determines the injection duration (control of
the injector coil for pre-injection, main injection and secondary
injection) and the injection pressure.
In the Euro 4 engines, the injectors are designed with two-stage
A Small ring surface
B Large surface
armatures.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 104
104/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 105
105/121
7/18/2019
Combustion pressure characteristic:
A
Pre-injection
B
Main injection
F
Secondary injection
MAN D0836_CR_en
The advantages of pre-injection:
The pressure rises uniformly and, as a result, the combustion noise is
reduced and the engine runs more smoothly.
PRE, MAIN, and SECONDARY INJECTION
take place across the whole characteristic.
Note:
Better particle reduction is achieved by the use of secondary
Exception:
injection (F). The particle discharge is strongly dependent on the
The 326 BHP D0836 LF44 engine has no pre-injection at higher
fuel-air mixture.
speeds and loads as the injector loading would be too high.
Advantages of secondary injection:

The TURBULENT charge movements are slower

More energy due to shorter injection

Unburned carbon burns off better

Has no effect on NOX
or better cleaning of individual cylinders.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 106
106/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 107
107/121
7/18/2019
SPEED SENSORS
MAN D0836_CR_en
Crankshaft speed sensor (3):
This sensor (3) is used to calculate the crank angle of the crankshaft
and is responsible for the correct timing of the injectors in the
intervals.
The synchronising mark ( 1) is an additional mark and is close to the
individual cylinders.
The Flywheel (A)
The phase marks are distributed over the segment gear at equal
has 60 divisions with 58 holes (two holes are
missing), which are spaced by 60 and with a gap of 180 (4). This gap
phase mark for the first cylinder to identify the 1st cylinder.
It is used to determine the angle of the engine within 720°.
is used to determine the angular position (3600 crankshaft) of the
engine and, in addition, to detect the crankshaft position of the 1st or
6th cylinder.
(TDC – Instant of injection)
C
Speed sensor signal from flywheel
D
Camshaft speed sensor signal
Camshaft speed sensor (2)
The camshaft rotates at half the speed of the crankshaft. Its position
determines whether a piston is on the compression or exhaust cycle.
The segment gear (B) on the camshaft is known as the phasing gear.
It has one phase mark per cylinder (altogether 6 marks and one
synchronising mark 1).
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 108
108/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 109
109/121
7/18/2019
MAN CATS 2 ENGINE DATA
MAN D0836_CR_en
Smooth running control:
Evaluation example: (always in ignition sequence)
The smooth running control is intended to achieve even running of
If the 6th cylinder has poor performance, the correction amount on
the engine, particularly at idle speeds.
injector 6 is increased.
In a six-cylinder engine, each cylinder accelerates the engine for
If the engine still does not run evenly after this, the quantity for the
120° in its working cycle. The control unit evaluates the running of the
2nd cylinder injector is also increased.
engine every 120° and drives the injectors of the "slowest" cylinders
However, after this, the quantity for all other cylinders is reduced so
for longer and those of the "fastest" cylinders for less time, as a result
that the engine does not run too fast.
of which the injection quantity varies.
The fuel correction amount is the deviation from the desired amount.
It is therefore possible to detect a group in which two injectors have
an increased amount (+) and the other injectors have a reduced
The ignition sequence 153624 must be taken into account
amount (-).
when carrying out the evaluation.
In this + + - group, the first cylinder is the one with the worst power
output.
In order to obtain an overview of the condition of the engine, when
carrying out comparative monitoring of the cylinders, the speed
and the (calculated) injection quantity should also be displayed.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 110
110/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 111
111/121
7/18/2019
ACCELERATION T EST
MAN D0836_CR_en
Prerequisites:
Engine at operating temperature > 750 C
The acceleration test can only be evaluated in conjunction with the
Drive vehicle until warm, do not leave running
compression test. This acceleration test only compares cylinders with
one another. The result must be consistent with the correction
To determine whether all injectors are injecting evenly, the speed that
amount.
the engine is able to reach with a defined injection quantity in a
certain time is measured in the acceleration test.


The average value, total of all cylinders, which lie at roughly the
same level

A deviation of about +- 25 from this average value is still
In the first acceleration test, all injectors are controlled and
the speed reached is determined.

Rule of thumb:
In the second acceleration test, the engine is accelerated
acceptable
again but with injector 1 disconnected.

The third acceleration test is carried out without injector 2, the
Rate of change of speed:
fourth to seventh acceleration tests without injector 3 to 6.

knocks)
If the engine now reaches almost the same speed as in the first
acceleration test in spite of the disconnected injector, then this
Value too high (no pre-injection or amount too low, engine

Value too low (quantity too large, engine knocks)
cylinder is not working well in motoring mode. (Check the engine
mechanics).
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 112
112/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 113
113/121
7/18/2019
COMPRESSION TEST
MAN D0836_CR_en
Procedure:
1 Battery 100% charged
Strong braking, i.e. a low speed before TDC, indicates relatively
2 Engine at operating temperature > 75 0 C
good compression.
3 Drive vehicle until warm, do not leave running
4 Follow the MAN-CATS 2 instructions quickly (otherwise no
A
Minimum speed (rpm) Measurement on the compression
cycle from ca. 8° before to 8° after TDC (maximum difference
evaluation)
3 rpm between the individual cylinders)
During the compression test, the engine is turned by the starter.
The control unit suppresses injection (engine does not start) and
B
Maximum speed (rpm) Measurement at ca. 70° before TDC
(maximum difference 3 rpm between the individual c ylinders)
measures how strongly the starter is braked on each cylinder during
C
Difference (rpm) Maximum difference 5 rpm between the
the compression cycle.
To do this, the starter must be activated by means of the ignition key
until the control unit has measured the speeds at TDC and shortly
individual cylinders
Remedies:
Adjust valves, valve damage, piston ring damage etc.
before BDC for all cylinders.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 114
114/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 115
115/121
7/18/2019
WATER PUMP
MAN D0836_CR_en
1
Coolant pump fixing bolts 23 Nm
Note:
2
Coolant pump
Smear sliding seal and coolant pump shaft with coolant according to
3
Coolant pump gasket
MAN standard 324 Type N before fitting.
4
Sliding seal
Press bearing (6) into the coolant pump as far as the stop with a
5
Impeller
suitable fitting tool.
6
Coolant pump bearing
(Do not touch the sliding seal with your fingers).
7
Circlip
8
Coolant pump hub
9
Fixing bolts
10
Coolant pump housing
11
Gasket
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 116
116/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 117
117/121
7/18/2019
MAN D0836_CR_en
COMPRESSOR
A single-cylinder air compressor with optionally 238 cm or 350 cm
1
2
Air compressor with resonance reservoir
O-ring, air compressor oil hole (Vaseline 09.15014-0001)
is used in the TG1.
3
Fixing bolt 23 Nm
4
O-ring, air compressor housing (techn. Vaseline 09.15014-
3
3
The air preparation system consists of a water-cooled single-cylinder
0001)
air compressor. It is located on the right-hand side of the engine and
5
Steering pump driving disc
is driven by a spur gear on the camshaft. The system is designed for
6
O-ring, steering pump (techn. Vaseline 09.15014-0001)
an effective pressure of 12.5 bar.
7
8
Steering pump with 20/16.6/14 cm /min
Fixing bolt, steering pump 23 Nm
The steering pump (impeller pump) with a flow volume of 20 cm3/min,
9
Overpressure valve, opening pressure 17 bar +- 2 bar (200 Nm)
3
16.6 cm3/min or 14 cm3/min is mounted on the rear face of the air
compressor.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 118
118/121
7/18/2019
MAN D0836_CR_en
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 119
119/121
7/18/2019
GLOW PLUG STARTING SYSTEM
1
Manual pump
2
FSC
3 /5
Fuel pipe
MAN D0836_CR_en
Ready to start

Terminal 15 on

Flame start relay clocked at f= 1 Hz at a voltage of > 21.5V

The flame start relay is continuously energised at a voltage of
2
4
Solenoid valve Y100 (17300 1 mm)
6
BERU glow plug R 100 (17301 62mm)
A
The central on-board computer controls the glow plug starting
< 21.5 Volt.

system.
B
The glow plug starting system is only actuated at a coolant
Flame start indicator LED flashes via I CAN at f = 1 Hz, 50%
TEXT: Start ENGINE

There is no voltage on flame start solenoid valve

If the engine is not started, at the end of the ready-to-start
temperature of < + 10 degrees C.
period (15 sec) the system starts to measure the dwell time
before restarting (dependent on the battery voltage)
Pre-heating time

Indicator LED (pre-heating) continuously controlled via I-CAN

The start relay K 102 is clocked with a v oltage of > 24 V. If the
voltage is < 24 V, the relay is permanently energised.

There is no voltage on the solenoid valve.

When the voltage is 22 - 23 V, the pre-heating time is ca. 33 - 35

TEXT: NEW PRE-HEATING
Terminal 50 on during ready ready-to-start
Flame start indicator lamp clocked via I – CAN as flame start
relay, TEXT: START ENGINE in the display
Flame start solenoid valve switches on
sec.
D:\Auto\TRUCK\MAN\MAN Series\Двигатель_Топливная система\Двигатели\en\D0836_CR_en.doc
http://slidepdf.com/reader/full/man-d0836cren
Page 120
120/121
7/18/2019
http://slidepdf.com/reader/full/man-d0836cren
MAN D0836_CR_en
121/121