Documente Academic
Documente Profesional
Documente Cultură
51.99493-8269
Preface
Dear Customer,
these Operating Instructions are intended to familiarize you with your new MAN Diesel
engine and how it operates.
The Publication “Fuels, Lubricants and Coolants for MAN Diesel Engines” supplements
these Operating Instructions.
Note:
Both publications apply to the engine and must always be kept to hand in its vicinity
in the engine room.
Please read this Manual and the “Instructions for the installation of MAN Diesel Engines”
before you put the new engine into operation.
Comply in full with instructions relating to operation, prevention of accidents and en-
vironmental protection.
MAN Diesel engines are developed and manufactured in line with the latest state of the
art. However, trouble-free operation and high performance can only be achieved if the
specified maintenance intervals are observed and only approved fuels, lubricants and
coolants are used.
It is imperative and in your own interest to entrust your MAN Local Service Centre with
the removal of any disturbances and with the performance of checking, setting, and re-
pair work.
Yours faithfully,
MAN Nutzfahrzeuge AG
Werk Nürnberg
1
Index
Page
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine views D 2848 LE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Maintenance chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2
Nameplates
Model
......................................................................
delivered on
......................................................................
installed on
......................................................................
MAN Nutzfahrzeuge Aktiengesellschaft Enter 14-digit serial number (is used in the
Typ spare parts catalog to distinguish between
Motor-Nr. / Engine No. spare parts).
NI/II
der number).
−0219
3
Safety regulations
General notes
Day-to-day use of power engines and the service products (fuels, lubricants, cool-
ants) necessary for running them presents no problems if the persons occupied
with their operation, maintenance and care are given suitable training and think as
they work.
This summary is a compilation of the most important regulations. These are broken down
into 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 by
the type of engine and its site are to be observed also.
Important:
If, despite all precautions, an accident occurs, in particular through contact with caustic
acids, fuel penetrating the skin, scalding from hot oil, anti-freeze being splashed in the
eyes etc., consult a doctor immediately.
D Before putting the engine into operation for the first time, read the oper-
ating instructions carefully and familiarize yourself with the “critical”
points. If you are unsure, ask your MAN representative.
D Do not touch the engine with bare hands when it is warm from operation
− risk of burns.
ËË
4
Safety regulations
D Exhaust gases are toxic. Comply with the instructions for the installation
of MAN Diesel engines which are to be operated in enclosed spaces.
Ensure that there is adequate ventilation and air extraction.
D Keep vicinity of engine, ladders and stairways free of oil and grease.
Accidents caused by slipping can have serious consequences.
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 the
elements of change-over filters, remember that there is a risk of scald-
ing. Do not get too close to rotating parts.
D Neither tighten up nor open pipes and hoses (lube oil circuit, coolant cir-
cuit 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.
5
Safety regulations
D When using compressed air, e.g. for cleaning the radiator, wear goggles.
6
Safety regulations
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 must
not be adjusted without prior written permission of MAN Nürnberg.
If faults occur, find the cause immediately and have it eliminated in order to prevent more
serious 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”.
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. See
“Maintenance and care”.
D Do not switch off the engine immediately when it is warm, but let it run without load for
about 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 on
the 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”.
7
Safety regulations
D Take strict precautions to ensure that no oil or Diesel fuel gets into the drains or the
ground.
The drinking water supply could be contaminated.
D Filter elements are classed as dangerous waste and must be treated as such.
Coolant
D When disposing of spent coolant comply with the regulations of the relevant local auth-
orities.
8
Safety regulations
Prolonged or repeated contact between the skin and any kind of engine oil decreases the
skin. Drying, irritation or inflammation of the skin may therefore occur. Used engine oil
also 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, health
risks 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.
For this reason do not let engine oil get into the ground, waterways, the drains or the
sewers. Violations are punishable.
Collect and dispose of used engine oil carefully. For information on collection points
please contact the seller, the supplier or the local authorities.
9
Technical information
1 2 3 4
9 8 7 6 5
12 10
11
10
Technical information
1 Turbocharger
4 Intercooler
5 Tensioning pulley
6 Water pump
7 Oil dipstick
8 Oil cooler
9 Oil filter
10 Injection pump
11 Starter motor
12 Fuel filter
11
Technical information
1 2 3 4
7 6 5
8 9
14 13 12 11 10
12
Technical information
1 Water pump
2 Fuel filter
4 Turbocharger
5 Starter motor
6 Oil dipstick
7 Alternator
9 Intercooler
10 Tensioning pulley
12 Oil cooler
13 Exhaust manifold
14 Oil filter
13
Technical information
Engines
The engines D 2848 / 40 / 42 LE are liquid-cooled 8-/ 10-/ 12-cylinder four-stroke Diesel
engines with direct injection, turbocharged and intercooled.
The cylinders are on a 90° V pattern.
Engine block
The forged crankshaft runs on 5-/ 6-/ 7-bearings and has screwed-on counterweights.
Radial seals with replaceable wearing rings on crankshaft and flywheel are provided to
seal the crankcase penetrations.
The connecting rods are die-forged, diagonally split and can be removed through the top
of the cylinders together with the pistons.
Crankshaft and connecting rods run in steel-backed lead bronze ready-to-fit type bear-
ings.
14
Technical information
Engine timing
Camshaft, oil pump and injection pump are driven by a gear train arranged at the fly-
wheel end.
The camshaft is located centrally in the “V” and runs on 5-/ 6-/ 7-bearings.
2
3
3
The crankshaft gear and camshaft gear are match-marked by the digit “1” or “D”.
Valves
The overhead valves are actuated via chilled cast iron tappets, push rods and rocker
arms from the camshaft.
15
Technical information
Engine lubrication
The pressure is produced by a gear pump whose drive gear is in direct mesh with the
crankshaft gear at the flywheel end.
The oil pump draws the oil from the oil sump and delivers it through the oil cooler and oil
filter to the main distributor gallery and from there to the main bearings, big-end bearings
and camshaft bearings as well as to the small-end bearings and the rocker arms.
The injection pump and the turbochargers are also connected to the engine lubricating
system.
Depending on the agreed extent of delivery and the design of the engine, the lube oil cir-
cuit can be equipped with oil pressure monitors (advance warning and cut-off function)
which shut the engine down in the event of a sudden loss of pressure.
8 10 15 17
18
16 1 2 3 2
16
Technical information
17 13 14 17
5 11
4
12
6
Oil cooler
An oil cooler is provided between the oil filter and the crankcase.
This cooler is of the flat tube type with turbulence inserts and operated by the engine
coolant.
17
Technical information
Fuel system
Fuel Circuit Diagram
4 5 3 7 2 6 8 9
5 3 7 8 2 6
18
Technical information
The fuel is delivered by the fuel lift pump via the fuel filter to the injection pump and from
there to the injectors.
The fuel is sprayed into the cylinder through four-hole nozzles fitted in screw-fit injectors
in the cylinder heads.
Excessive fuel delivered and leak fuel from the injectors flow through the return pipe back
to the tank.
Injection pump
The in-line injection pump is driven via gears from the crankshaft.
It is connected to the force-feed lubricating system of the engine and consequently main-
tenance-free.
The centrifugal governor flange-mounted on the pump casing is a variable range gover-
nor designed to keep the speed set by the control lever constant under conditions of
varying load
The governor has a full load stop controlled by the charge-air pressure and is designed
to decrease the full load fuel quantity in the low speed range from a certain (adjustable)
charge-air pressure onwards.
Fuel filters
Before entering the suction chamber of the injection pump, the fuel is passed through
two primary fuel filters located in the engine vee and finally cleaned in a two-stage, paral-
lel or changeover filter.
19
Technical information
Turbocharger
The exhaust gases of the engine are passed through the turbine rotors of the two turbo-
chargers.
Air impellers mounted on the same shaft draw in fresh air and deliver it at a higher pres-
sure to the cylinders.
D
1
2
A B
20
Technical information
D 2
A B
1 E
1 D 2
A B
21
Technical information
Intercooler
Before entering the cylinders the combustion air compressed in the turbocharger is
passed through a heat exchanger (intercooler).
Heat removal in the cooler is either by air (air-to-air intercooler) or, in case of the marine
application, by means of seawater (air-to-water intercooler) delivered by the raw water
pump.
In the case of extended standstills, cleaned seawater may be left in the intercooler, but
dirty water (brackish water) must definitely be discharged.
Cooling
The water pump is a maintenance-free impeller pump and is driven by V-belts from the
crankshaft pulley.
Depending on the agreed extent of delivery and the design of the engine, the cooling cir-
cuit can be equipped with temperature and level monitors which, in the event of over-
heating, will trigger an advance warning system or, in the event of loss of coolant, shut
the engine down.
Air cleaner
Air cleaners are mounted on the engine to purify the air for combustion.
The intervals at which the air cleaners require servicing depend on the specific operating
conditions encountered.
Clogged air filters may cause black smoke and reduce power.
A check should be made from time to time to see that the fastening elements securing
the air cleaners to the intake manifolds seal the connection tightly.
Any ingress of unfiltered air is liable to cause a high rate of cylinder and piston wear.
22
Technical information
Electrical equipment
Alternator
Operate the alternator according to the instructions given in the chapter “Commission-
ing and operation”.
Starter motor
The sliding-gear starter motor is flanged to the rear of the flywheel housing on the right-
hand side.
As part of every engine overhaul, the starter pinion and ring gear should be cleaned with
a brush dipped in fuel and then a coat of grease should be applied again.
Warning:
Always disconnect the battery earth cable before starting work on the electrical sys-
tem. Connect up the earth cable last, as there is otherwise a risk of short-circuits.
23
Commissioning and operation
Proceed as follows:
D Fill with minimum oil quantity recom-
mended for the respective engine type.
1 After this initial filling wait about
1/2 hour until the entire oil has col-
lected in the oil sump
D Pull out dipstick and mark minimum oil
level visible on dipstick
D Thereafter fill up to maximum oil sump
2 capacity, wait about 1/2 hour and mark
maximum oil level visible on dipstick
D After refilling with oil, rotate the engine
with the starter and move the shut-
1 Oil dipstick down lever to “stop” at the same time
2 Oil drain plug until the oil pressure warning light goes
out and the oil pressure gauge shows a
Before daily starting the engine, check pressure. Then start the engine and al-
fuel level, coolant level and engine oil low it to run at medium speed for a few
level and replenish, if necessary. minutes. Check oil pressure and tight-
ness of system. Then shut down the
Replenish oil through the filler neck on the
engine. After about 20 minutes, check
valve cover.
the oil level. The oil level should now be
at the upper notch of the dipstick, but
not higher.
1
Add any necessary oil to the upper dip-
stick mark
Caution:
Do not add so much engine oil that the
oil level rises above the max. marking
on the dipstick. Overfilling will result in
damage to the engine.
24
Commissioning and operation
Running in
Raw water pump It is recommended that new or overhauled
engines should not be operated at a load
Do not let raw water pump run dry. higher than about 75% maximum load
Make sure that all valves / cocks in the during the first few hours of operation. Ini-
raw water circuit are open. tial run-in should be at varying speeds.
If there is a risk of frost, drain the raw wa- After this initial run-in, the engine should
ter pump. be brought up to full output gradually.
After ignition of the engine, release the During operation the oil pressure in the
starter button and adjust control lever for engine lubrication system must be moni-
desired speed. tored. If the monitoring devices register a
drop in the lube oil pressure, switch off the
If engine fails to start, release the key, engine immediately.
wait about 30 seconds, then operate
starter again. The coolant temperature should be
approx. 80 to 85°C.
25
Commissioning and operation
26
Maintenance and care
Oil drainage
27
Maintenance and care
1 Left-hand filter
cut out
8
Caution:
4 Do not leave selector lever in any in-
termediate position because this
would be liable to interfere with oil
7 supply.
28
Maintenance and care
Injection pump
1 Fuel strainer
No alterations must be made to the injec-
2 Filtering screen
tion pump. If the lead seal is damaged the
3 Filter housing
warranty on the engine will become null
and avoid.
After every 200 hours of operation the fuel
strainer connected upstream of the fuel lift
Faults
pump should be cleaned.
We urgently recommend that you have
faults in the injection pump rectified only in
Fuel filter
an authorised specialist workshop.
After every 1000 hours of operation − or
Bleeding the fuel system
earlier if loss of engine power indicates
clogging − the filter elements should be
Bleeding the fuel filters is by releasing the
renewed.
bleed screws and operating the manual
primer (fit new seals).
29
Maintenance and care
1
3
1
2
1
30
Maintenance and care
Parallel fuel filter with interchangeable Change-over fuel filter with filter car-
filter tridges
(replaced by change-over fuel filter with
The fuel flows through two parallel filters. interchangeable filter)
4 4 7
3
9
10 8
1 Filter cartridge 5
2 Screw plug
3 Bleed screw 1
4 Moisture drain plugs 6
11
2
12
Draining moisture:
Unscrew drain plugs at every oil change
until moisture has been discharged and 1 Changeover type filter
clean fuel flows out. 2 Collecting vessel
3 Cover for collecting vessel
Replacement of filter elements: 4 O-ring
After every 1000 hours of operation − or 5 Gasket
earlier if loss of engine power indicates 6 Fixing bolts for collecting vessel
clogging − the filter elements should be 7 Wing nut
renewed. 8 Filler plug
9 Vent plug
Caution: 10 Fixing nut
Used fuel filters are classed as dan- 11 Sludge drain plug
gerous waste and must be disposed of (socket head width across flats 5)
accordingly. 12 Selector lever
31
Maintenance and care
Left-hand filter
cut out 1 Filter cartridge
2 Bleed screw
3 Selector lever
32
Maintenance and care
The injector consists of the nozzle and the Polish needle seat with wooden cleaning
nozzle holder. tool, preferably by chucking the needle in
a lathe at the pintle end.
A copper gasket fitted to the injector en-
sures gas-tight seating and good heat dis- Clean the spray holes of hole nozzles us-
sipation. ing the cleaner KDEP 2900/2 by chucking
a cleaning needle of suitable diameter in
The opening pressure of the nozzle is ad- the collet. If the carbon deposits in the
justed by means of shims at the compres- spray holes cannot be removed by rotat-
sion spring. ing and pressing, have the needle project
only slightly from the collet and drive out
the carbon by lightly tapping on the tool.
33
Maintenance and care
Caution:
The injection lines are designed for
high operating pressures and should
thus be handled with particular care.
34
Maintenance and care
Draining of coolant
35
Maintenance and care
36
Maintenance and care
d) Warm up engine under load. After a D Drain the pickling fluid, fill the system
temperature of 60°C is reached, run with tap water, and run the engine at
engine for a further 15 minutes idle for 5 minutes to flush out all fluid;
e) Drain cleaning fluid then drain the water
f) Repeat steps c) and d) D Fill the system with a 1% soda solution.
g) Flush cooling system. To this effect Drain the soda solution after running
h) Replace drain plug by drain plug with a the engine at idle for 5 minutes, and
bore of 8 mm dia. flush with tap water until the discharg-
i) Fill cooling system with hot water ing water is clear
k) Run engine at idle for 30 minutes. At D Fill cooling circuit with a mixture of po-
the same time continuously replenish table tap water and anti-freeze with at
the water leaking from the bore in drain least 40% by volume, refer to Publica-
plug by adding fresh water tion “Fuels, Lubricants ...”
37
Maintenance and care
38
Maintenance and care
The turbochargers do not call for any spe- Measuring of axial clearance
cific maintenance.
Special hints
39
Maintenance and care
Intercooler
A
Maintenance
(by authorized specialist personnel)
If excessive clearances are found, the Be sure to clean the sealing surfaces
turbocharger should be replaced. carefully before installing the gaskets.
40
Maintenance and care
Dust collector
41
Maintenance and care
42
Maintenance and care
Safety cartridge
When the main cartridge is being serviced The maintenance intervals for filters de-
the safety cartridge remains in the filter pend on the respective operating condi-
housing. The engine must not be run with- tions.
out the main cartridge.
As soon as a distinct layer of dust has
Safety cartridges must be neither cleaned accumulated on the filter element, remove
nor re-used. air cleaner and wash in fuel or cleaning
oil.
Safety cartridges must be changed:
D at the latest after being in use for two Shake element out thoroughly to dry it.
years
D if, after the main cartridge has been Uniformly coat filter surface with a thin film
serviced (changed), the contamination of engine oil.
gauge responds again immediately
D if the main cartridge is defective
43
Checking and setting
To check and set the start of deliv- For the purpose of checking the start-of-
ery with start of delivery marker delivery setting, an “OT” (top dead centre)
on injection pump hub mark and a scale from 10 ... 40° or 50°
(by authorized specialist personnel) before top dead centre are engraved on a
disc fitted in front of the torsional vibration
D 2840 LE damper. The scale marks are read against
a pointer fitted to the crankcase.
1 Pointer
2 “OT” (top dead centre) mark and scale
3 Hexagon driver to rotate engine by
hand (Width across flats 32)
44
Checking and setting
Remove screw plug in timing housing Correct start of delivery by turning the
cover above injection pump drive gear. pump drive flange in the slotted holes of
the drive gear.
45
Checking and setting
To check and set the start of deliv- For the purpose of checking the start-of-
ery with start of delivery indicator delivery setting, an “OT” (top dead centre)
in the governor housing mark and a scale from 10 ... 40° or 50°
(by authorized specialist personnel) before top dead centre are engraved on a
disc fitted in front of the torsional vibration
D 2840 LE damper. The scale marks are read against
a pointer fitted to the crankcase.
1 Pointer
2 “OT” (top dead centre) mark and scale
3 Hexagon driver to rotate engine by
hand (Width across flats 32)
46
Checking and setting
Checking
1 2
47
Checking and setting
30
15
ø3
ø11
48
Checking and setting
49
Checking and setting
50
Checking and setting
1 4
Spare part No. 51.97801−0211
Note: MAN
The cylinder head bolts to be retigh-
Exhaust side
tened must not be loosened first, but
simply tightened by a further 90° (1/4
Tightening diagram “1”
revolution) from their actual position.
51
Checking and setting
Before inserting the cylinder head bolts oil After the first 10 to 20 hours of operation
them with engine oil on the thread (not to after a repair turn the cylinder head bolts
the bore) and coat the contact face of the by a further 90° (1/4 revolution) in the or-
bolt head with “Optimoly White T” assem- der shown in Tightening diagram “2”.
bly paste. Do not use any oils or oil addi-
tives that contain MoS2. The bolts must be The cylinder head bolts to be retightened
tightened by the angle-of-rotation method must not be loosened first, but simply
as shown in Tightening diagram “2”. tightened by a further 90° (1/4 revolution)
from their actual position.
Intake side / injector
Attach the sticker “First retightening of
6 cylinder head bolts ...” (Remove any
other stickers which may already be at-
tached).
1 4
After the first 400 hours of operation after
a repair tighten cylinder head bolts 1 to 4
in the order shown in Tightening diagram
“1” again by a further 90° (1/4 revolution).
MAN 5
Note:
Exhaust side When a cylinder head has been re-
moved the cylinder head gasket must
D 1st pretightening step = to 10 Nm always be changed.
D 2nd pretightening step = to 80 Nm
D 3rd pretightening step = to 150 Nm
D 4th pretightening step = turn by 90°
D Final tightening = turn by 90°
52
Checking and setting
Permissible maximum lengths are 111, Check V-belts for cracks, oil, overheating
146 and 170 mm respectively. and wear.
Change demaged V-belts.
Checking tension
90+3
L Use V-belt tension tester to check V-belt
tension.
L = Shank length
Checking with tension measuring
device
Surface
The surface of the bolts must be in satis-
1
factory condition, i.e. the phosphate coat-
ing must be intact and there must be no
rust.
53
Checking and setting
2
1
3
Reading of tension
1
D Read of the tensioning force of the belt
at the point where the top surface of
the indicator arm À intersects with the
scale
D Before taking readings make ensure
that the indicator arm remains in its
position
54
Notes
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55
Technical data
Model D 2848 LE
Design V-form, 90°
Cycle 4-stroke Diesel with turbocharger and in-
tercooler
Combustion system Direct injection
Turbocharging Turbocharger with intercooler
Number of cylinders 8
Bore 128 mm
Stroke 142 mm
Swept volume 14 620 cm3
Compression ratio 15.5 : 1
Rating see engine nameplate
Firing order 1−5−7−2−6−3−4−8
Valve clearance (cold engine)
Intake 0.25 mm
Exhaust 0.40 mm
Valve clearance changed Starting from engine no ...7678 001....
Intake 0.50 mm
Exhaust 0.60 mm
See instruction label on valve cover
Valve timing
Intake opens 24° before TDC
Intake closes 36° after BDC
Exhaust opens 63° before BDC
Exhaust closes 27° after TDC
Fuel system
Injection In-line pump, V-saddle-mounted
Governor All speed type
Injection timer Automatic centrifugal type in camshaft
drive gear
Injectors four-hole nozzles
Opening pressure of injector
Injector + injection nozzle New nozzle holder: Used nozzle holder:
51.10101-7274 220 + 8 bar 220 + 8 bar
51.10101-7290 235 + 8 bar 220 + 8 bar
56
Technical data
57
Technical data
Model D 2840 LE
Design V-form, 90°
Cycle 4-stroke Diesel with turbocharger and in-
tercooler
Combustion system Direct injection
Turbocharging Turbocharger with intercooler
Number of cylinders 10
Bore 128 mm
Stroke 142 mm
Swept volume 18 270 cm3
Compression ratio 15.5 : 1
Rating see engine nameplate
Firing order 1−6−5−10−2−7−3−8−4−9
Valve clearance (cold engine)
Intake 0.25 mm
Exhaust 0.40 mm
Valve clearance changed Starting from engine no ...7666 042....
Intake 0.50 mm
Exhaust 0.60 mm
See instruction label on valve cover
Valve timing
Intake opens 24° before TDC
Intake closes 36° after BDC
Exhaust opens 63° before BDC
Exhaust closes 27° after TDC
Fuel system
Injection In-line pump, V-saddle-mounted
Governor All speed type
Injection timer Automatic centrifugal type in camshaft
drive gear
Injectors four-hole nozzles
Opening pressure of injector
Injector + injection nozzle New nozzle holder: Used nozzle holder:
51.10101-7274 220 + 8 bar 220 + 8 bar
51.10101-7290 235 + 8 bar 220 + 8 bar
58
Technical data
59
Technical data
Model D 2842 LE
Design V-form, 90°
Cycle 4-stroke Diesel with turbocharger and in-
tercooler
Combustion system Direct injection
Turbocharging Turbocharger with intercooler
Number of cylinders 12
Bore 128 mm
Stroke 142 mm
Swept volume 21 930 cm3
Compression ratio 15.5 : 1
Rating see engine nameplate
Firing order 1−12−5−8−3−10−6−7−2−11−4−9
Valve clearance (cold engine)
Intake 0.25 mm
Exhaust 0.40 mm
Valve clearance changed Starting from engine no ...7651 046....
Intake 0.50 mm
Exhaust 0.60 mm
See instruction label on valve cover
Valve timing
Intake opens 24° before TDC
Intake closes 36° after BDC
Exhaust opens 63° before BDC
Exhaust closes 27° after TDC
Fuel system
Injection In-line pump, V-saddle-mounted
Governor All speed type
Injection timer Automatic centrifugal type in camshaft
drive gear
Injectors four-hole nozzles
Opening pressure of injector
Injector + injection nozzle New nozzle holder: Used nozzle holder:
51.10101-7274 220 + 8 bar 220 + 8 bar
51.10101-7290 235 + 8 bar 220 + 8 bar
60
Technical data
61
Maintenance chart
Maintenance cycles *
Maintenance jobs
1 2 3 4 5 6 7 8 9
Check coolant level and oil level in engine D
Check air filter contamination D
Change engine oil in oil sump (see also page 63) D d d d
Change oil filter cartridge (see also page 63) D d d d
Clean fuel strainer D D
Draining fuel filter / condensation
D
(earlier if severe operating conditions demand it)
Check and if necessary correct V-belt tension D D
1st retightening of cylinder head bolts
D
(with overhauled engine)
Check that removable unions (bolts, hose clips, pipe fit-
D
tings) are firmly in position and, if necessary, retighten
Service the air cleaner
D
(earlier if severe operating conditions demand it)
2nd retightening of cylinder head bolts
D
(with new or overhauled engine)
Check and if necessary adjust valve clearance D D D
Change disposable fuel filter / filter elements D
Check turbocharger D
Change coolant D
Renew filler cap and working valve of cooling system D
Check injection nozzles D
* 1 − Daily
2 − After the first 10 to 20 hours of operation (with new or overhauled engine)
3 − Every 200 hours of operation
4 − After the first 400 hours of operation
5 − Every 400 hours of operation
6 − Every 1000 hours of operation
7 − Every 3000 hours of operation
8 − Every 2 years
9 − Every 5000 hours of operation for engines in permanent operation
and peak load operation
Every 48 months for engines in standby generators
d Oil change interval in hours of operation depends on oil grade used. See page 63.
62
Maintenance chart
Engine oil change intervals in hours of operation, depending on the oil grade used.
*) See Publication “Fuels, Lubricants and Coolants for MAN Diesel Engines”.
Note:
D Use only approved engine oils
D Where Diesel fuels with a sulphur content greater than 1% are used, the oil change
intervals are to be halved
D Irrespective of the periods stated, the engine oil should be changed at least once ev-
ery year
D Change the oil filter elements every time the engine oil is changed
63
Index
A N
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22, 41 Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23, 26
O
C Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Checking and setting . . . . . . . . . . . . . . . . . . . . . . 44 Oil drainage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Checking V−belts . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Commissioning and operation . . . . . . . . . . . . . . . 24
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22, 35 P
Cooling circuit Piston / Conrod / Crank assembly . . . . . . . . . . . 14
Cleaning the inside of tube bundles of raw water Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Descaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 R
Cleaning the outside of the radiator . . . . . . . . 36 Raw water pump . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Filler caps and working valves . . . . . . . . . . . . . 38 Refilling with oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Internal cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 36 Running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Cylinder head bolts . . . . . . . . . . . . . . . . . . . . 50 − 53
S
D Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Draining of coolant . . . . . . . . . . . . . . . . . . . . . . . . 35 Handling used engine oil . . . . . . . . . . . . . . . . . . . 9
During operation . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Preventing accidents with injury to persons . . . 4
Preventing damage to engine and premature
E wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . 23 Preventing environmental damage . . . . . . . . . . 8
Engine block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Shutting down . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Engine lubrication . . . . . . . . . . . . . . . . . . . . . . 16, 27 Sources of supply for pickling fluids . . . . . . . . . . 38
Engine oil change . . . . . . . . . . . . . . . . . . . . . . . . . 63 Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Engine views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
T
F Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Filling−in of coolant . . . . . . . . . . . . . . . . . . . . . . . . 35 Technical information . . . . . . . . . . . . . . . . . . . . . . 10
Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19, 29 Temporary decommissioning . . . . . . . . . . . . . . . . 26
Fuel lift pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 To check and adjust valve clearance . . . . . . . . . 49
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . 18, 29 To check and set the start of delivery . . . . . . . . . 44
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . 20, 39
I
Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . 19, 29 V
Injector maintenance . . . . . . . . . . . . . . . . . . . . . . . 33 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22, 40
W
L Waste water treatment . . . . . . . . . . . . . . . . . . . . . 38
Lubricating oil filter . . . . . . . . . . . . . . . . . . . . . . . . 28
M
Maintenance and care . . . . . . . . . . . . . . . . . . . . . 27
Maintenance chart . . . . . . . . . . . . . . . . . . . . . . . . . 62
Marking the dipstick . . . . . . . . . . . . . . . . . . . . . . . 24
64
MAN Nutzfahrzeuge AG
Vogelweiherstraße 33
90441 Nuremberg
Germany