CLAAS Forage Harvesters D2862 LE131-138 MAN Industrial Diesel Engines Repair Manual – PDF DOWNLOAD

Description

CLAAS Forage Harvesters D2862 LE131-138 MAN Industrial Diesel Engines Repair Manual – PDF DOWNLOAD

DESCRIPTION:

CLAAS Forage Harvesters D2862 LE131-138 MAN Industrial Diesel Engines Repair Manual – PDF DOWNLOAD

Preface

• This repair manual is intended to provide assistance in performing repairs correctly on vehicles and units. The technical details were correct at the time of going to press.
• This publication assumes that persons who use it possess the requisite technical knowledge in handling vehicles and units. Pictures and the corresponding descriptions are typical snapshots; they do not always correspond to the unit in question or its peripherals, but this does not necessarily mean they are incorrect. In cases such as these, plan and execute the repair
• measures accordingly. Repair work on complex attachment units should be entrusted to our customer service or to the customer service of the manufacturing company. These units are mentioned specifically in the text.
• The repair jobs are divided up into sections and subsections. Each subsection starts with a page of jobs to do in advance. The jobs to do in advance contain a summary of the main prerequisites for the repair section in question.
• A detailed description of work can follow the jobs to do in advance. Important instructions concerning technical safety and the safety of personnel are specifically highlighted, as indicated below.

TABLE OF CONTENTS:

CLAAS Forage Harvesters D2862 LE131-138 MAN Industrial Diesel Engines Repair Manual – PDF DOWNLOAD

1 Preface 7
11 Preface 7
2 Safety instructions 9
21 Explanation of icons 9
22 General 9
23 Requirements of personnel 10
24 Regulations to prevent accidents with personal injury 10
25 Regulations for avoiding injury and environmental contamination 12
26 Liability limitations for replacement parts and accessories 12
27 Guidelines for preventing damage and premature wear on the engine 13
28 Limp-home program for engines with an electronic control unit 13
29 Information for working on the common rail system 14
210 Handling DEF 15
211 Engine overhaul 15
212 Assembly information 16
3 Engine electrical system 17
31 Switch, cable harness, sensors 17
311 Cable harnesses, plug connector, vertical 17
3111 Removing/installing the charge pressure sensor 17
3112 Removing/installing the EDC fuel temperature sensor 19
3113 Removing/installing the pressure sensor 21
3114 Removing/installing the rail pressure sensor/transmitter (common rail) 24
3115 Removing/installing the oil pressure sensor (left) 28
3116 Removing/installing the oil pressure sensor (right) 30
3117 Removing/installing the engine oil temperature sensor 33
3118 Removing/installing the coolant temperature sensor 36
3119 Removing/installing the crankshaft speed sensor 39
31110 Removing/installing the camshaft speed sensor 42
312 Other electrical devices 45
3121 Removing/installing EDC control unit (Electronic Diesel Control) 45
32 Measurement and display devices, sensors 50
321 Temperature and diameter 50
33 Electric machines, devices 51
331 Three-phase alternator 51
3311 Removing/installing the alternator 51
332 Starter motor 56
3321 Removing/installing the starter/starter motor 56
4 Engine 61
41 Cooling system (water cooling) 61
411 Coolant line 61
4111 Removing/installing the coolant pump coolant manifold 61
4112 Removing/installing the air compressor coolant line 63
4113 Removing/installing the coolant manifold on the engine block (left) 67
4114 Removing/installing the coolant manifold on the engine block (right) 70
4115 Removing/installing the coolant line for the heater supply 74
4116 Removing/installing the coolant line on the cylinder head (left) 76
4117 Removing/installing the coolant line on the cylinder head (right) 79
412 Coolant temperature control, thermostat 83
4121 Removing/installing the thermostat housing coolant manifold 83
4122 Removing/installing the thermostat housing 85
4123 Removing/installing the thermostat insert 89
413 Coolant pump components 94
4131 Removing/installing the coolant pump 94
42 Exhaust, intake manifold, air filter 97
421 Intake pipe, intake manifold components 97
4211 Removing/installing the charge-air manifold/air distributor pipe 97
4212 Removing/installing the intake manifold/air distributor pipe (left) 100
4213 Removing/installing the intake manifold/air distributor pipe (right) 103
422 Exhaust manifold components 107
Index of contents 3
Observe the safety instructions Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and
material damage Before commencing work, ensure that the latest documentation is used
4221 Removing/installing the turbocharger exhaust pipe connector (left) 107
4222 Removing/installing the turbocharger exhaust pipe connector (right) 108
4223 Removing/installing the exhaust manifold (left) 110
4224 Removing/installing the exhaust manifold (right) 112
4225 Dismantling/assembling the exhaust manifold 114
43 Engine control 117
431 Valve / valves 117
4311 Checking/adjusting valve/valves 117
4312 Removing/installing the valve stem seals 122
432 Rocker arm components 129
4321 Checking the rocker arm 129
4322 Removing/installing the rocker arm mechanism 131
4323 Dismantling/assembling the rocker arm mechanism 133
4324 Checking the rocker arm bracket 135
433 Camshaft components 137
4331 Removing/installing the camshaft 137
434 Camshaft drive 142
4341 Checking the valve timing 142
4342 Removing/installing the camshaft gear 144
44 Cylinder head 147
441 Removing/installing the cylinder head 147
441 Cylinder head cover components 155
4411 Removing/installing the cylinder head cover 155
45 Engine lubrication, automatic clean oil replenisher 159
451 Oil filter 159
4511 Removing/installing the oil filter insert 159
4512 Removing/installing the oil module (left) 161
4513 Removing/installing the oil module (right) 165
4514 Dismantling/assembling the oil module 169
452 Oil cooler 176
4521 Removing/installing the heat exchanger/engine oil cooler 176
453 Oil pipe, intake basket, oil screen 178
4531 Removing/installing the oil pump suction line manifold 178
4532 Removing/installing the oil pump suction line/intake pipe 179
454 Oil intake and return pump 182
4541 Removing/installing the oil pump 182
455 Oil sump and automatic clean oil replenisher 185
4551 Removing/installing the oil sump 185
4552 Dismantling/assembling the oil sump 188
46 Crankshaft drive 191
461 V-belt drive 191
4611 Removing/installing the alternator V-belt 191
4612 Removing/installing the automatic belt tensioner 192
4613 Removing/installing the ribbed V-belt guide roller 194
462 Vibration damper components 197
4621 Removing/installing the vibration damper 197
463 Flywheel components 201
4631 Removing/installing the flywheel 201
4632 Removing/installing flywheel ring gear 207
464 Crankshaft components, engine barring gear 210
4641 Mounting/removing the engine cranking unit 210
4642 Coolant pump crankshaft gear 211
4643 Removing/installing the coolant pump intermediate gear 213
4644 Dismantling/assembling the coolant pump intermediate gear 215
4645 Removing/installing the crankshaft gear (front) 217
4646 Removing/installing the crankshaft gear (rear) 219
4647 Removing/installing the crankshaft 220
4648 Checking the crankshaft 237
465 Piston components 241
4651 Checking the piston protrusion 241
4652 Removing/installing the piston with connecting rod 242
4653 Dismantling and assembling the piston with connecting rod 248
4654 Checking the piston with connecting rod 250
4 Index of contents
Observe the safety instructions Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and
material damage Before commencing work, ensure that the latest documentation is used
47 Engine housing 257
471 Front plate and timing case components 257
4711 Removing/installing the end cover 257
472 Flywheel housing, engine flange 259
4721 Removing/installing the flywheel housing 259
4722 Dismantling/assembling the flywheel housing 260
473 Housing sealing components 265
4731 Removing/installing the rear crankshaft radial shaft seal 265
4732 Removing/installing the front crankshaft radial shaft seal 269
474 Cylinder liners 273
4741 Removing/installing the cylinder liner 273
475 Piston spray cooling 278
4751 Removing/installing the oil nozzle 278
476 Vent with filter and oil filler neck 280
4761 Removing/installing the crankcase ventilation (left) 280
4762 Removing/installing the crankcase ventilation (right) 281
4763 Removing/installing the crankcase ventilation oil separator (left) 283
4764 Removing/installing the crankcase ventilation oil separator (right) 285
48 Turbocharging 288
481 Intake manifold 288
4811 Intake fitting, left turbocharger 288
4812 Intake fitting, right turbocharger 289
482 Exhaust turbine, oil pipe 293
4821 Removing/installing the turbocharger (left) 293
4822 Removing/installing the turbocharger (right) 298
5 Fuel / exhaust system 307
51 Fuel system components 307
511 Fuel filter 307
5111 Removing/installing the fuel filter insert 307
5112 Removing/installing the fuel service center 310
5113 Dismantling/assembling the fuel service center 313
512 Fuel lines 320
5121 Removing/installing the fuel line 320
5122 Removing/installing the fuel return line (left) 331
5123 Removing/installing the fuel return line (right) 335
52 Injection nozzle 340
521 Pressure line, injector nozzle components 340
5211 Removing/installing the pump – rail CR pressure line 340
5212 Removing/installing the injection pressure line (left) 345
5213 Removing/installing the injection pressure line (right) 350
5214 Removing/installing the rail (left) 355
5215 Removing/installing the rail (right) 359
5216 Removing/installing the common rail pressure-limiting valve 363
522 Injector nozzle components 367
5221 Removing/installing the injector with nozzle (common rail) 367
53 Injection pump (actuation) 376
531 Injection pump, check valve 376
5311 Removing/installing the high pressure pump (front) 376
5312 Removing/installing the high pressure pump (rear) 379
5313 Dismantling/assembling the high-pressure pump 383
5314 Removing/installing the high-pressure pump drive housing 390
5315 Dismantling and assembling the high-pressure pump drive housing 392
532 Control unit console 398
5321 Removing/installing the cooling plate/console for the control unit (EDC) 398
54 Engine attachments 401
541 Alternator attachment components 401
5411 Removing/installing the alternator bracket 401
542 Engine suspension 403
5421 Removing/installing the crane lifting eye / engine lifting eye 403
6 Air compressor, pressure control valve 407
61 Air compressor, line 407
611 Removing/installing the air compressor (single cylinder) 407
612 Dismantling/assembling air compressor (single cylinder) 411
Index of contents 5
Observe the safety instructions Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and
material damage Before commencing work, ensure that the latest documentation is used
613 Removing/installing the air compressor cap 422
7 Power take-off 425
71 Engine-dependent power take-off components 425
711 Removing/installing the PTO cover 425
8 Hydraulic power steering components, engine suspension 427
81 Engine suspension 427
811 Removing/installing the engine bracket (left) 427
812 Removing/installing the engine bracket (right) 428
9 Hydraulics, air-conditioning system working devices 431
91 Air-conditioning 431
911 Removing/installing the refrigerant compressor 431
Indexes 435
Special tools 435
6 Index of contents
Observe
IMAGES PREVIEW OF THE MANUAL:

CLAAS FORAGE HARVESTERS D2862 LE131-138 MAN INDUSTRIAL DIESEL ENGINES REPAIR MANUAL – PDF DOWNLOAD:

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