man 2848 le operation manual

3Operating Instructions MAN Marine Diesel Engines

Preface

5

Dear Customer,these Operating Instructions are intended to familiarize you with your new MAN Dieselengine and how it operates.This manual is supplemented by the publication Fuels, Lubricants and Coolants for MANDiesel Engines and the Service record book.

Note:All three publications belong to the engine and must always be kept ready to handnear the engine in the engine room.Comply in full with instructions relating to operation, prevention of accidents and envi-ronmental protection.

MAN Diesel engines are developed and manufactured in line with the latest state of theart. However, trouble-free operation and high performance can only be achieved if thespecified maintenance intervals are observed and only approved fuels, lubricants andcoolants are used.

It is imperative and in your own interest to entrust your MAN Local Service Centre withthe removal of any disturbances and with the performance of checking, setting, and re-pair work.

Yours faithfully,MAN Nutzfahrzeuge AktiengesellschaftNuremberg works

Subject to change to keep abreast with technological progress.

2002 MAN Nutzfahrzeuge AktiengesellschaftNo parts of this publication may be reproduced or translated without prior written permis-sion of MAN. MAN explicitly reservs all rights according to copyright law.

MTDA Technical status: 02.2002 51.994938498

Contents

6

Declaration 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nameplates 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety regulations 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Commissioning and operation 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine views 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . First commissioning 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commissioning 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation monitoring system 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shutting down 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance and care 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication system 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel system 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling system 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-belts 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temporary decommissioning of engines 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical data 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting table 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For data see original declaration

If required this declaration is enclosed with the delivery note.

Declaration

7

Declaration

In accordance with Article 4, paragraph 2, in conjunction with Appendix II, section B, ofDirective 89/392/EEC, version 93/44/EEC

MAN Nutzfahrzeuge Aktiengesellschaft,

hereby declares that the engine described below is destined for installation in a machineas defined in the EC directive on machines.

Engine model:

Design:

Engine number:

Rating / speed:

Note:The manufacturer of the complete ready-to-use machine in which this engine is to beinstalled must take the further action necessary in the context of indirect safety-re-lated engineering and provision of instructions to ensure that the ready-to-usemachine complies with the requirements of the EC directive on machines.

The engine must not be put into operation until the complete machine satisfies theconditions laid down in the EC directive on machines 89/392/EEC, most recentlyamended by 93/44/EEC, or the latest amendment of said directive.

MAN Nutzfahrzeuge Aktiengesellschaft

Vogelweiherstrae 33

D90441 Nrnberg

Nameplates

8

In all your correspondence please alwaysquote engine model, serial number and jobnumber (Order number).

For this reason it is advisable to read off thedata from the engine type plates beforeputting the engine into operation and toenter them in the appropriate spaces.

The engine type plates are on the crank-case (see illustration).

Model

......................................................................

delivered on

......................................................................

installed on

......................................................................

Engine serial number

......................................................................

Order number

......................................................................

MAN Nutzfahrzeuge AktiengesellschaftTyp

Motor-Nr. / Engine No.NI/II

Temp. C

Werk Nrnberg Germany:

MAN Nutzfahrzeuge AktiengesellscMAN Nutzfahrzeuge Aktiengesellschaft

: : Altitude mRating BHP

Job No Rating kW Speed rpm

Serial NoModelYear

0219

Aufstellhohe m uNNLeistg. PS

Drehz. 1/minLeistung kWWerkNr.

MotorNr.TypBauj.

Safety regulations

9

General notesHandling diesel engines and the necessary resources is no problem when the per-sonnel commissioned with operation and maintenance are trained accordinglyand use their common sense.

This summary is a compilation of the most important regulations. These are broken downinto main sections which contain the information necessary for preventing injury to per-sons, damage to property and pollution. In addition to these regulations those dictated bythe type of engine and its site are to be observed also.

Important:If, despite all precautions, an accident occurs, in particular through contact with causticacids, fuel penetrating the skin, scalding from hot oil, anti-freeze being splashed in theeyes etc., consult a doctor immediately.

1. Regulations designed to prevent accidents with injury to persons

During commissioning, starting and operation

D Before putting the engine into operation for the first time, read the oper-ating instructions carefully and familiarize yourself with the criticalpoints. If you are unsure, ask your MAN representative.

D For reasons of safety we recommend you attach a notice to the door ofthe engine room prohibiting the access of unauthorized persons andthat you draw the attention of the operating personal to the fact thatthey are responsible for the safety of persons who enter the engineroom.

D The engine must be started and operated only by authorized personnel.Ensure that the engine cannot be started by unauthorized persons.

D When the engine is running, do not get too close to the rotating parts.Wear close-fitting clothing.

D Do not touch the engine with bare hands when it is warm from oper-ation risk of burns.

D Exhaust gases are toxic. Comply with the instructions for the installationof MAN Diesel engines which are to be operated in enclosed spaces.Ensure that there is adequate ventilation and air extraction.

Safety regulations

10

D Keep vicinity of engine, ladders and stairways free of oil and grease. Accidents caused by slipping can have serious consequences.

During maintenance and care

D Always carry out maintenance work when the engine is switched off. If the engine has to be maintained while it is running, e.g. changing theelements of change-over filters, remember that there is a risk of scald-ing. Do not get too close to rotating parts.

D Change the oil when the engines is warm from operation.Caution:There is a risk of burns and scalding. Do not touch oil drain plugs or oilfilters with bare hands.

D Take into account the amount of oil in the sump. Use a vessel of suffi-cient size to ensure that the oil will not overflow.

D Open the coolant circuit only when the engine has cooled down. If opening while the engine is still warm is unavoidable, comply with theinstructions in the chapter entitled Maintenance and Care.

D Neither tighten up nor open pipes and hoses (lube oil circuit, coolantcircuit and any additional hydraulic oil circuit) during the operation. The fluids which flow out can cause injury.

D Fuel is inflammable. Do not smoke or use naked lights in its vicinity.The tank must be filled only when the engine is switched off.

D When using compressed air, e.g. for cleaning the radiator, weargoggles.

D Keep service products (anti-freeze) only in containers which can not beconfused with drinks containers.

D Comply with the manufacturers instructions when handling batteries.Caution:Accumulator acid is toxic and caustic. Battery gases are explosive.

Safety regulations

11

2. Regulations designed to prevent damage to engine and premature wear

Do not demand more from the engine than it is able to supply in its intended application.Detailed information on this can be found in the sales literature. The injection pump mustnot be adjusted without prior written permission of MAN Nuremberg.

If faults occur, find the cause immediately and have it eliminated in order to prevent moreserious damage.

Use only genuine MAN spare parts. MAN will accept no responsibility for damage result-ing from the installation of other parts which are supposedly just as good.

In addition to the above, note the following points:

D Never let the engine run when dry, i.e. without lube oil or coolant.

D When starting do not use any additional starting aids (e.g. injection with starting pilot).

D Use only MAN-approved service products (fuel, engine oil, anti-freeze and anti-cor-rosion agent). Pay attention to cleanliness. The Diesel fuel must be free of water. SeeMaintenance and care.

D Have the engine maintained at the specified intervals.

D Do not switch off the engine immediately when it is warm, but let it run without load forabout 5 minutes so that temperature equalization can take place.

D Never put cold coolant into an overheated engine. See Maintenance and care.

D Do not add so much engine oil that the oil level rises above the max. marking onthe dipstick. Do not exceed the maximum permissible tilt of the engine. Serious damage to the engine may result if these instructions are not adhered to.

D Always ensure that the testing and monitoring equipment (for battery charge, oil pres-sure, coolant temperature) function satisfactorily.

D Comply with instructions for operation of the alternator. See Maintenance and care.

D Do not let the raw water pump run dry. If there is a risk of frost, drain the pump whenthe engine is switched off.

Safety regulations

12

3. Regulations designed to prevent pollution

Engine oil and filter elements / cartridges, fuel / fuel filter

D Take old oil only to an old oil collection point.

D Take strict precautions to ensure that no oil or Diesel fuel gets into the drains or theground.The drinking water supply could be contaminated.

D Filter elements are classed as dangerous waste and must be treated as such.

Coolant

D Treat undiluted anti-corrosion agent and / or anti-freeze as dangerous waste.

D When disposing of spent coolant comply with the regulations of the relevant local auth-orities.

Safety regulations

13

4. Notes on safety in handling used engine oil

Prolonged or repeated contact between the skin and any kind of engine oil decreases theskin. Drying, irritation or inflammation of the skin may therefore occur. Used engine oilalso contains dangerous substances which have caused skin cancer in animal experi-ments. If the basic rules of hygiene and health and safety at work are observed, healthrisks are not to the expected as a result of handling used engine oil.

Health precautions:D Avoid prolonged or repeated skin contact with used engine oil.D Protect your skin by means of suitable agents (creams etc.) or wear protective gloves.D Clean skin which has been in contact with engine oil.

Wash thoroughly with soap and water. A nailbrush is an effective aid. Certain products make it easier to clean your hands. Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.

D After washing apply a fatty skin cream to the skin.D Change oil-soaked clothing and shoes.D Do not put oily rags into your pockets.

Ensure that used engine oil is disposed of properly Engine oil can endanger the water supply

For this reason do not let engine oil get into the ground, waterways, the drains or thesewers. Violations are punishable.

Collect and dispose of used engine oil carefully. For information on collection pointsplease contact the seller, the supplier or the local authorities.

Adapted from Notes on handling used engine oil.

Commissioning and operation

14

Engine views D 2842 LE 401

1 2 3

9 10 11

7

4 5 6

8 12

1413

15

1718 1619


15

1 Heat exchanger and coolant surge tank

2 Coolant filler neck

3 Intercooler

4 Relief valve on coolant surge tank

5 Oil filler neck

6 Air intake

7 Water pump (engine coolant circuit)

8 Oil drain plug

9 Oil dipstick

10 Starter motor

11 Exhaust pipe, liquid-cooled

12 Waste Gate

13 Turbocharger, liquid-cooled

14 Oil separator valve for crankcase breather

15 Engine cranking device

16 Oil sump

17 Oil cooler

18 Connection for oil pressure sensor

19 Oil filter


16

First commissioning

When putting a new or overhauled engine into operation for the first time pay attention tothe Installation instructions for MAN marine diesel engines without fail.

It is recommended that new or overhauled engines should not be operated at a loadhigher than about 75% maximum load during the first few hours of operation. Initial run-inshould be at varying speeds. After this initial run-in, the engine should be brought up tofull output gradually.

Note:Use only approved fuels, lubricants etc. (see brochure Fuels, lubricants etc.). Otherwise the manufacturers warranty will become null and void.

Filling with fuel

Caution:Fill the tank only when the engine is switched off. Pay attention to cleanliness. Do not spill fuel.Use only approved fuels (see Fuels, Lubricants etc.)

Filling-in of coolant

Fill the cooling system of the engine with a mixture of drinkable tap water and anti-freezeagent on ethylene glycole basis or anti-corrosion agent.See Publication Fuels, Lubricants and Coolants for MAN Diesel Engines.

D Pour in coolant slowly via expansion tank, see page 31D For coolant filling quantity, see Technical data


17

Raw water pump

Do not let raw water pump run dry.

Make sure that all valves / cocks in theraw water circuit are open.

If there is a risk of frost, drain the raw wa-ter pump.

Filling with engine oil

Caution:Do not add so much engine oil that theoil level rises above the max. markingon the dipstick. Overfilling will result indamage to the engine.

The engines are as a rule supplied with-out oil.Pour oil into engine via filler neck (arrow),see page 25.For the quantity required see TechnicalData.

Oil


18

Commissioning

Before daily starting the engine, check fuel level, coolant level and engine oil level andreplenish, if necessary.


Checking oil level

Check engine oil level only approx. 20 minutes after the unit has beenswitched off.

D Pull out dipstick (arrow)

D wipe it with a clean, lintfree cloth

D and push it in again up to the stop

D Pull out dipstick again

The oil level should be between the twonotches in the dipstick and must never fallbelow the lower notch. Top up oil as nec-essary.


Ensure outmost cleanliness when han-dling fuels, lubricants and coolants.

Oil

?

MINMAX


19

Starting

Danger:Before starting make sure that no-one is in the engines danger area.

Ensure that the gearbox is in neutral.

Caution:When starting do not use any additional starting aids (e.g. injection with starting pilot).

Insert starter key and turn it to position I. The check lamp comes on to show that theengine is ready for operation.

Turn starter key further to position II (pre-glow). The display lamp (usually in the driversstation) comes on.

After the pre-glow period the display lamp begins to flash. This signalizes that the engineis ready for starting.

Note:If the engine is not equipped with a pre-glowing function, immediately turn the starterkey through to position III.

Turn key further up to the stop (position III). The display lamp goes out. The starter mo-tor is actuated.

Lube oil pressure must build up at the oil pressure gauge. If it does not, switch off the en-gine immediately.

For cold engines (


20

For repeated starting turn the key back to OFF.

If the engine is kept idling for long periods it may cool down and thus start to emit whiteor blue smoke.We therefore recommend that you do not let the engine idle for more than 5 minutes.It is well known that with any internal combustion engine wear is higher during idling.Idling for longer periods is also an environmental nuisance.


21

Operation monitoring system

Caution:Do not overload the engine. Do not exceed the maximum permissible engine tilt.If faults occur, find their cause immediately and have them eliminated in order to pre-vent more serious damage!

During operation the oil pressure in theengine lubrication system must be moni-tored. If the monitoring devices register adrop in the lube oil pressure, switch off theengine immediately.

Operation of the engine monitoring system

The engine monitoring system warns theship operator if important engine operat-ing values are outside the permissible tol-erance range.

The display unit of the engine monitoringsystem (see picture) is installed in themain navigating stand and, as an option,in the secondary navigating stand (fly-bridge) too. The alarm is raised:

D acoustically by means of a hornD visually by the flashing of the respective

red check lamp (exception: in the eventof a fault in the electronic system therespective check lamp is permanentlyilluminated)

To protect the engine, the speed will bereduced if alarm warnings like engine oilpressure, engine coolant temperature,charge-air temperature and coolant level)is raised. The check lamp reducedspeed is then illuminated permanently.


22

Note on engines with electronically controlled diesel injection (EDC):After the ignition has been switched on, the lamp Fault in the electronic system willcome on momentarily (lamp check). If there is a fault in the electronically controlleddiesel injection system (EDC), the lamp Fault in the electronic system will be illumi-nated permanently.

Operation of the engine monitoring system after an alarm has been triggered

The display unit has the following operating buttons:

Switching off of the alarm horn.

Switching off of the flashing signal of the respective check lamp, ie the flashinglight changes into permanent light. Before the flashing signal can be switched off,the alarm horn must be switched off.

Lifting of the alarm message (the red check lamp will go out).Precondition for lifting an alarm message:

D Pressing of buttons Horn off and Test in the order indicatedD Elimination of the cause of the alarmD Short-term reduction of the engine speed below 800 rpm, to again achieve higher en-

gine speeds

Functional test of the check lamps

If no alarm is raised, the check lamps may be checked. Upon pressing the buttonTest, all check lamps must come on.


23

Self-test of system

To achieve optimum operational reliability, the system distinguishes between sensor faultand real alarm.

The following sensors are checked forsensor fault and parting of wire:

D Engine speedD Engine oil pressureD Coolant temperatureD Charge-air temperatureD Coolant level

If the signal sent by the sensor is a valuewhich does not occur in practice or if thewire connection is interrupted, the checklamp Sensor fault and the check lamp ofthe associated function will start flashing.

Shutting down

After the engine has been running at ahigh load level, do not shut it down imme-diately but allow it to idle about 5 minutesso that temperatures may equalize.

Set deck switch to Neutral and switch offthe engine at the stop button / ignition key.

Remove key from starting lock.

Danger:Ensure that the engine can notbe started by unauthorized per-sons.

Maintenance and care

24

Lubrication system

Ensure outmost cleanliness when handling fuels, lubricants and coolants.


Engine oil change

Danger:The oil is hot- risk of scalding.Do not touch the oil drain plugwith bare fingers. Oil is an envi-ronmental hazard. Handle it withcare!

With the engine at operating temperature,remove the oil drain plugs on the oil sumpand the oil filter bowl and allow the old oilto drain off completely.

Use a vessel of sufficient size to ensurethat the oil does not overflow.

As the oil drain plug is often not accessi-ble, a manually operated vane pump maybe attached to the engine for draining theoil.

Pump the old oil out of the sump while theengine is still warm. Remove oil drainplugs in oil filter bowl and let old oil drainout of oil filters. Use a vessel of sufficientsize to ensure that the oil does not over-flow.

Refit the oil drain plugs with new gaskets.

Note:Change the oil filter elements everytime the engine oil is changed


25

Refilling with oil


Refill with fresh engine oil at the oil fillerneck (arrow).

After filling start the engine and let it runfor a few minutes at low speed.

Caution:If no oil pressure builds up after ap-prox. 10 seconds switch off the engineimmediately.

Check oil pressure and check that there isno oil leakage.Then shut down the engine. After about 20 minutes, check the oil level.

D Pull out dipstick (arrow)

D wipe it with a clean, lintfree cloth

D and push it in again up to the stop

D Pull out dipstick again

The oil level should be between the twonotches in the dipstick and must never fallbelow the lower notch. Top up oil as nec-essary.

Changing oil filter

A changeover-type oil filter, the filter ele-ments of which can be replaced even dur-ing operation, can be fitted on request.

However, oil filter cartridges must bechanged at every oil change.

Oil

Oil

?

MINMAX


26

During continuous operation position theselector lever that both filter halves are inoperation.Observe positions of selector lever!

Caution:Do not leave selector lever in anyintermediate position because thiswould be liable to interfere with oilsupply. If in doubt stop engine tochange oil filter.

Renewal of filter cartridgesD Allow the filter content to run off along

drain plugs . Hold a suitable vessel under hole

Danger:The oil is hot and under pressurewhen the drain plug is opened.Risk of burns and scalds.

D After releasing the clamping bolts remove filter bowls

D Renew filter cartridges . Thoroughlyclean all other parts in cleaning fluid(do not allow cleaning fluid to enter theoil circuit)

D Use new gaskets for reassembly offilter bowls

Note:To prevent the seal from twistinghold the filter bowl firmly when tight-ening the tensioning screw .

Caution:Used oil filters are classed as danger-ous waste and must be disposed ofaccordingly.

Continuous operation(both filter halves in operation)Right-hand filter cut out

Left-hand filter cut out

1

4

2

4

36

5

7

8

1 Oil filter, standard design (non-changeover)

2 Oil filter, changeover-type3 Selector cock4 Oil drain plugs5 Filter cartridge6 O-ring7 Filter bowl8 Clamping bolt


27

Fuel system

Fuel

If Diesel fuel which contains moisture is used the injection system and the cylinder liners/ pistons will be damaged. This can be prevented to same extent by filling the tank assoon as the engine is switched off while the fuel tank is still warm (formation of con-densation is prevented). Drain moisture from storage tanks regularly. Installation of a wa-ter trap upstream of the fuel filter is also advisable. Do not use any additives to improveflow properties in winter.

Injection pump

Neither the injection pump nor the control unit must be modified in any way. If the leadseal is damaged the engine warranty will become null and void.

Faults

We urgently recommend that you have faults in the injection pump rectified only in an au-thorized specialist workshop.

Cleaning fuel pre-cleaner

D Strip the fuel pre-cleaner

D Wash out filter housing and filter bas-ket in clean fuel

D Fit new seals

D Actuate tappet of hand primer untiloverflow valve of injection pump isheard to open

D Screw in the tappet of the hand pumpagain and tighten it

D Start engine

D Check fuel pre-cleaner for leaks

1 2

3

4


28

Parallel fuel filter

Draining moisture:Unscrew drain plugs at every oil changeuntil moisture has been discharged andclean fuel flows out.

Changing fuel filterOnly when engine is switched off

D Loosen filter with tape wrench andremove it

D Wet seal on new filter with fuelD Screw on filter by handD After this, bleed the fuel systemD Check filter for leaks

Caution:Used fuel filters are classed as dan-gerous waste and must be disposed ofaccordingly.

Change-over fuel filter

Where the changeover-type filter isinstalled, the servicing procedure is for thefilter side requiring to be shut off with theengine running. During continuous oper-ation, the selector lever should be placedin a position where both filter halves are inoperation.

Caution:Do not leave selector lever in anyintermediate position because thiswould be liable to interfere with fuelsupply. If in doubt stop the engine tochange the fuel filter.

Continuous operation(both filter halves in operation)Right-hand filter cut out

Left-hand filter cut out


29

Changing fuel filter

D Loosen filter with tape wrench andremove it

D Wet seal on new filter with fuelD Screw on filter by handD After this, bleed the fuel systemD Check filter for leaks

Caution:Used fuel filters are classed as dan-gerous waste and must be disposed ofaccordingly.

Bleeding the fuel system

Note:To bleed the fuel system switch on theignition so that the EHAB will beopen.

An arrow on the filter head indicates thedirection of fuel flow.

D Unscrew bleed screw of first filter indirection of flow by one or two turns

D Actuate tappet of hand primer until fuelemerges without bubbles

D Screw in the tappet of the hand pumpagain and tighten it

D Close bleed screw again

D Repeat this procedure at the secondbleed screw

D Check filter for leaks


30

Cooling system

Danger:Draining hot coolant involves a risk of scalding.

Draining the cooling system

Caution:Drain coolant into a suitable containerand dispose of it in accordance withregulations.

Drain coolant as follows, but only whenthe engine has cooled down.

D Briefly open cap (, large cap) on thefiller neck of the expansion tank forpressure compensation

D Remove drain plug in crankcase , oilcooler housing and exhaust manifold

D Then remove cap

D Drain coolant into a container of ade-quate size

D Refit screw plugs

D Filling / bleeding the cooling system

1

2

3

4

2


31

Filling / bleeding the cooling system (only when engine has cooled down)

Fill the cooling system of the engine with a mixture of drinkable tap water and anti-freezeagent on ethylene glycole basis or anti-corrosion agent.See Publication Fuels, Lubricants and Coolants for MAN Diesel Engines.

Coolant must be added at the filler neck only (, large cap). When topping up do notadd cold coolant if the engine is still warm from operation.Ensure that the ratio of water to anti-freeze is correct. Find the cause of the loss of cool-ant and have it eliminated.

D Remove cap (, large cap)

D Fill in the coolant slowly

D During the filling operation the liquidcooled turbochargers are to be bled.For this purpose an oval flange with ableeder screw is located on the rearside of the turbine housing. Thisbleeder screw must remain open untilcoolant emerges free of bubbles or untilthe coolant level has reached the fillerneck (depending on the installationsituation)

D Let engine run at a speed of 2,000 rpmfor approx. 15 minutes

D Switch off engine, carefully turn cap with safety valve to the first detent torelieve pressure and then carefully re-move cap and top up with coolant

Danger:Risk of scalding and burningyourself!

1

2


32

D Before the engine is next put into operation (with the engine cold) check the coolantlevel and top up if necessary

D Repeat this procedure until no more coolant can be added

Note:The turbochargers must not be bled while the cooling system is being topped up.

Danger:If, in an exceptional case, the coolant level has to be checked in an engine thathas reached operating temperature, first carefully turn the cap (, large cap)with safety valve to the first stop, let off pressure, then open carefully.


33

V-belts

Checking condition

If, in the case of a multiple belt drive, wearor differing tensions are found, always re-place the complete set of belts.

D Check V-belts for cracks, oil, overheat-ing and wear

D Change demaged V-belts

Checking tension

Use V-belt tension tester to check V-belttension.

D Lower indicator arm into the scaleD Apply tester to belt at a point midway

between two pulleys so that edge ofcontact surface is flush with the V-belt

D Slowly depress pad until the springcan be heard to disengage. This willcause the indicator to move upwards

If pressure is maintained after the springhas disengaged a false reading will be ob-tained!

Reading of tension

D Read of the tensioning force of the beltat the point where the top surface ofthe indicator arm intersects with thescale

D Before taking readings make ensurethat the indicator arm remains in itsposition

If the value measured deviates from thesetting value specified, the V-belt tensionmust be corrected.

1

2

3

Drive

Tensioning forces according tothe kg graduation on the tes-

terDrivebeltidth

New installation Whenservicingwidth

Installa-tion

After 10min. run-ning time

servicingafter

long run-ning time

9.5 4550 4045 3010.0 4550 3540 3012.5 5055 4550 3513.0 5055 4045 3520.0 75 70 6022.0 75 70 60

2/3VX 90100 7080 603/3VX 135150 105120 90


34

Tensioning and changing V-belt

D Remove fixing bolts D Remove lock-nut D Adjust nut until V-belts have correct

tensionsD Retighten lock-nut and fixing bolts

To replace the V-belts loosen lock-nut andswing alternator inwards.

1

3

1

2

Alternator

The alternator is maintenance-free.Nevertheless, it must be protected against dust and, above all, against moisture.

In order to avoid damage to the alternator, observe the following instructions:

While the engine is runningD Do not de-energize the main battery switch!D Do not disconnect the battery or pole terminals or the cables!D If, durig operation, the battery charge lamp suddenly lights up, stop the engine im-

mediately and remedy the fault in the electrical system!D Do not run the engine unless the battery charge control is in satisfactory order!D Do not short-circuit the connections of the alternator with those of the regulator or said

connections with ground, not even by briefly bringing the connections into contact!D Do not operate the alternator without battery connection!

Temporary decommissioning of engines

Temporary anti-corrosion protection according to MAN works norm M 3069 is required forengines which are to be put out of service for fairly long periods.

The works standard can be obtained from our After-Sales Service department in Nurem-berg.

Notes

35

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Technical data

36

Model D 2848 LE 401 / 403 / 405Design V 90Cycle 4-stroke Diesel with turbocharging /

intercooling and wastegateCombustion system Direct injectionTurbocharging Turbocharger with intercooling

and wastegateNumber of cylinders 8Bore 128 mmStroke 142 mmSwept volume 14 620 cm3

Compression ratio 13.5 : 1Rating see engine nameplateFiring order 15726348Valve clearance (cold engine)

Intake 0.25 mmExhaust 0.40 mm

Valve clearance changed from engine No. ... 7678 001 ....Intake 0.50 mmExhaust 0.60 mm

See instruction label on valve coverValve timing

Intake opens 24 before TDCIntake closes 36 after BDCExhaust opens 63 before BDCExhaust closes 27 after TDC

Technical data

37

Fuel systemInjection In-line pump, V-saddle-mountedGovernor Centrifugal governor (variable-range

speed governor) with smoke stopStart of delivery

D 2848 LE 401 22 1 before TDCD 2848 LE 403

up to engine No. ... 9211 019 ....from engine No. ... 9211 020 ....

24 1 before TDC18 1 before TDC

D 2848 LE 405up to engine No. ... 9261 016 ....from engine No. ... 9261 017 ....

21 1 before TDC15 1 before TDC

Injectors five-hole nozzlesOpening pressure of injector

New nozzle holder: 295 + 8 barUsed nozzle holder: 280 + 8 bar

Engine lubrication Force feedOil capacity in oil sump (litres) min. max.

deep 12 l 18 lshallow 20 l 24 l

Oil change quantity (with filter)deep 21 lshallow 27 l

Oil pressure during operation (depend-ing on oil temperature, oil viscosityclass and engine rpm)

must be monitored by oil pressure moni-tors / gauges

Oil filter Full flow filter with two paper cartridgesEngine cooling system Liquid cooling

Coolant temperature 8085C, temporarily 90C allowedCoolant filling quantity 63 l

Electrical equipmentStarter 24 V; 5,4, 6.5 kWAlternator 28 V; 55, 110, 120, 225 A

Technical data

38

Model D 2840 LE 401 / 402 / 407Design V 90Cycle 4-stroke Diesel with turbocharging /








Technical data

39


speed governor) with smoke stopStart of delivery

D 2840 LE 401 24 1 before TDCD 2840 LE 402

with optimised consumptionwith optimised NOx

15 0,5 before TDC12 0,5 before TDC

D 2840 LE 407with optimised consumptionwith optimised NOx


InjectorsD 2840 LE 401 / 407 five-hole nozzlesD 2840 LE 402 six-hole nozzles

Opening pressure of injectorNew nozzle holder: 295 + 8 barUsed nozzle holder: 280 + 8 bar


deep (front end sump) 14 l 22 ldeep (rear end sump) 26 l 30 lshallow 26 l 30 l

Oil change quantity (with filter)deep (front end sump) 25 ldeep (rear end sump) 33 lshallow 33 l





Electrical equipmentStarter 24 V; 6.5 kWAlternator 28 V; 55, 110, 120, 225 A

Technical data

40

Model D 2842 LE 401 / 402 / 403 / 406 / 408D 2842 LE 411 / 412 / 413

Design V 90Cycle 4-stroke Diesel with turbocharging /









speed governor) with smoke stop

Technical data

41

Start of deliveryD 2842 LE 401 / 402 22 0,5 before TDCD 2842 LE 403

with optimised consumptionwith optimised NOx






D 2842 LE 411 18 0,5 before TDCD 2842 LE 412 13 0,5 before TDCD 2842 LE 413 16 0,5 before TDC

InjectorsD 2842 LE 401 / 402 / 406 / 408 / 411 five-hole nozzlesD 2842 LE 403 / 412 / 413 six-hole nozzles

Opening pressure of injectorNew nozzle holder: 295 + 8 barUsed nozzle holder: 280 + 8 bar


deep 24 l 32 lsemi-shallow 22 l 30 lfor 38 / 45 tilt 37 l 45 l

Oil change quantity (with filter)deep 35 lsemi-shallow 33 lfor 38 / 45 tilt 48 l





Electrical equipmentStarter 24 V; 6.5 kWAlternator 28 V; 55, 120, 225 A

Troubleshooting table

42

FaultEngine does not start, or starts only with difficulty

Engine starts but does not reach full speed or stallsEngine idles out of true when warm, misfiring

Engine speed fluctuates during operationPower output unsatisfactory

Coolant temperature too high, coolant being lostLube oil pressure too low

Lube oil pressure too highBlack smoke accompanied by loss of power

Blue smokeWhite smoke

Knocking in the engineEngine too loud

ReasonD Fuel tank emptyD Fuel cock closedD D D D D Air in fuel systemD D D D D Fuel pre-filter / pre-cleaner cloggedD Condensation in fuelD D D D Air filter cloggedD Electric circuit interruptedD Batteries flatD Starter / solenoid switch defectiveD D D D D Start of delivery not correct / incorrectly setD Injection nozzles cloggedD Internal damage to engine

(piston seized, possibly caused by water in fuel)D D D Fuel quality not in accordance with specifications or fueled

severely contaminatedD Lower idling speed set too low

D D D D Valve clearance incorrectD Injection nozzles of injection pipes leakingD Too little fuel in tankD Rev. counter defectiveD D D Injection nozzles defective or carbonizedD Engine being asked to do more than it has toD Fuel supply faulty, fuel too warmD D Oil level in sump too highD Incorrect rated speed settingD Coolant level too lowD Air in coolant circuit

Troubleshooting table

43

FaultEngine does not start, or starts only with difficulty

Engine starts but does not reach full speed or stallsEngine idles out of true when warm, misfiring

Engine speed fluctuates during operationPower output unsatisfactory

Coolant temperature too high, coolant being lostLube oil pressure too low

Lube oil pressure too highBlack smoke accompanied by loss of power

Blue smokeWhite smoke

Knocking in the engineEngine too loud

ReasonD Tension of water-pump V-belts incorrect (slip)D Cap with working valves on expansion tank / radiator defec-

tive or leakingD Temperature gauge defectiveD Coolant pipes leaking, blocked or twistedD Oil level in sump too lowD Engine temperature too highD Oil filter cloggedD D Oil pressure gauge defectiveD D Selected oil viscosity not suitable for ambient temperature

(oil too thin)D Oil in sump too thin (mixed with condensation or fuel)D Engine cold

D D Engine, coolant or intake air still to coldD Lube oil getting into combustion chamber

(piston worn, piston rings worn or broken)D Overpressure in crankcase (crankcase breather clogged)D long operation under a low loadD Coolant getting into combustion chamber

(cylinder head / gasket leaking)D Engine operating temperature incorrectD Intake or exhaust pipe leaking

Index

44

AAlternator 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BBleeding the fuel system 29. . . . . . . . . . . . . . . . . . .

CChanging oil filter 25. . . . . . . . . . . . . . . . . . . . . . . . . . Checking oil level 18. . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning fuel pre-cleaner 27. . . . . . . . . . . . . . . . . . . Commissioning 18. . . . . . . . . . . . . . . . . . . . . . . . . . . Commissioning and operation 1423. . . . . . . . . . . . Cooling system 3032. . . . . . . . . . . . . . . . . . . . . . . .

DDeclaration 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draining the cooling system 30. . . . . . . . . . . . . . . . .

EEngine oil change 24. . . . . . . . . . . . . . . . . . . . . . . . . Engine views 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FFilling / bleeding the cooling system 31. . . . . . . . . . Filling with engine oil 17. . . . . . . . . . . . . . . . . . . . . . . Filling with fuel 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . Filling-in of coolant 16. . . . . . . . . . . . . . . . . . . . . . . . First commissioning 1617. . . . . . . . . . . . . . . . . . . . Fuel filters 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing fuel filter 28, 29. . . . . . . . . . . . . . . . . . . . Draining moisture 28. . . . . . . . . . . . . . . . . . . . . . . .

Fuel system 2729. . . . . . . . . . . . . . . . . . . . . . . . . . .

IInjection pump 27. . . . . . . . . . . . . . . . . . . . . . . . . . . .

LLubrication system 2427. . . . . . . . . . . . . . . . . . . . .

MMaintenance and care 2434. . . . . . . . . . . . . . . . . .

NNameplates 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OOperation monitoring system 2123. . . . . . . . . . . . .

RRaw water pump 17. . . . . . . . . . . . . . . . . . . . . . . . . . Refilling with oil 25. . . . . . . . . . . . . . . . . . . . . . . . . . .

SSafety regulations 913. . . . . . . . . . . . . . . . . . . . . . .

Handling used engine oil 13. . . . . . . . . . . . . . . . . . Preventing accidents with injury to persons 9. . . Preventing damage to engine and prematurewear 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preventing environmental damage 12. . . . . . . . .

Shutting down 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting 1920. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TTechnical data 3641. . . . . . . . . . . . . . . . . . . . . . . . . Temporary decommissioning 34. . . . . . . . . . . . . . . . Troubleshooting table 4243. . . . . . . . . . . . . . . . . . .

VV-belts 3334. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating InstructionsPrefaceContentsDeclarationNameplatesSafety regulationsCommissioning and operationEngine views D 2842 LE 401First commissioningCommissioningStartingOperation monitoring systemShutting down

Maintenance and careLubrication systemFuel systemCooling systemV-beltsAlternatorTemporary decommissioning of engines

Technical dataTroubleshooting tableIndex

man 2848 le operation manual

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